Apparatus for fluid catalytic cracking oligomerate

ABSTRACT

Distillate cracks to propylene more readily than VGO. Additionally, less branched hydrocarbons crack to propylene more readily than more branched hydrocarbons. Oligomerization to diesel range oligomers followed by catalytic cracking with less branched oligomers can provide more propylene.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from Provisional Application No.61/725,323 filed Nov. 12, 2012, the contents of which are herebyincorporated by reference.

BACKGROUND

When oligomerizing light olefins within a refinery, there is frequentlya desire to have the flexibility to make high octane gasoline, highcetane diesel, or combination of both. However, catalysts that make highoctane gasoline typically make product that is highly branched andwithin the gasoline boiling point range. This product is veryundesirable for diesel. In addition, catalysts that make high cetanediesel typically make product that is more linear and in the distillateboiling point range. This results in less and poorer quality gasolinedue to the more linear nature of the product which has a lower octanevalue.

The oligomerization of butenes is often associated with a desire to makea high yield of high quality gasoline product. There is typically alimit as to what can be achieved when oligomerizing butenes. Whenoligomerizing butenes, dimerization is desired to obtain gasoline rangematerial. However, trimerization and higher oligomerization can occurwhich can produce material heavier than gasoline such as diesel. Effortsto produce diesel by oligomerization have failed to provide high yieldsexcept through multiple passes.

When oligomerizing olefins from a fluid catalytic cracking (FCC) unit,there is often the desire to maintain a liquid phase within theoligomerization reactors. A liquid phase helps with catalyst stabilityby acting as a solvent to wash the catalyst of heavier species produced.In addition, the liquid phase provides a higher concentration of olefinsto the catalyst surface to achieve a higher catalyst activity.Typically, this liquid phase in the reactor is maintained byhydrogenating some of the heavy olefinic product and recycling thisparaffinic product to the reactor inlet.

To maximize propylene produced by the FCC unit, refiners may contemplateoligomerizing FCC olefins to make heavier oligomers and recyclingheavier oligomers to the FCC unit. However, some heavy oligomers may beresistant to cracking down to propylene.

The products of olefin oligomerization are usually mixtures of, forexample, olefin dimers, trimers, and higher oligomers. Further, eacholefin oligomer is itself usually a mixture of isomers, both skeletaland in double bond location. Highly branched isomers are less reactivethan linear or lightly branched materials in many of the downstreamreactions for which oligomers are used as feedstocks. This is also trueof isomers in which access to the double bond is sterically hindered.Olefin types of the oligomers can be denominated according to the degreeof substitution of the double bond, as follows:

TABLE 1 Olefin Type Structure Description I R—HC═CH₂ Monosubstituted IIR—HC═CH—R Disubstituted III RRC═CH₂ Disubstituted IV RRC═CHRTrisubstituted V RRC═CRR Tetrasubstitutedwherein R represents an alkyl group, each R being the same or different.Type I compounds are sometimes described as α- or vinyl olefins and TypeIII as vinylidene olefins. Type IV is sometimes subdivided to provide aType IVA, in which access to the double bond is less hindered, and TypeIVB where it is more hindered.

SUMMARY OF THE INVENTION

We have discovered that distillate cracks to propylene more readily thanVGO. Additionally, less branched hydrocarbons crack to propylene morereadily than more branched hydrocarbons. Consequently, oligomerateproduct can be fed or recycled to an FCC unit to increase production ofpropylene.

An object of the invention is to produce oligomers that can be readilycracked down to propylene molecules.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of the present invention.

FIG. 2 is an alternative schematic drawing of the present invention.

FIG. 3 is a plot of C₈-C₁₁ olefin selectivity versus normal buteneconversion.

FIG. 4 is a plot of C₁₂+ olefin selectivity versus normal buteneconversion.

FIG. 5 is a plot of reactant conversion versus total butene conversion.

FIG. 6 is a plot of normal butene conversion versus reactor temperature.

FIGS. 7 and 8 are plots of butene conversion versus total buteneconversion.

FIG. 9 is a plot of selectivity versus maximum reactor bed temperature.

FIGS. 10-12 are bar graphs of conversion and yield for three differentcatalysts.

FIG. 13 is a plot of C₃ olefin yield versus VGO conversion.

DEFINITIONS

As used herein, the term “stream” can include various hydrocarbonmolecules and other substances. Moreover, the term “stream comprising Cxhydrocarbons” or “stream comprising Cx olefins” can include a streamcomprising hydrocarbon or olefin molecules, respectively, with “x”number of carbon atoms, suitably a stream with a majority ofhydrocarbons or olefins, respectively, with “x” number of carbon atomsand preferably a stream with at least 75 wt % hydrocarbons or olefinmolecules, respectively, with “x” number of carbon atoms. Moreover, theterm “stream comprising Cx+ hydrocarbons” or “stream comprising Cx+olefins” can include a stream comprising a majority of hydrocarbon orolefin molecules, respectively, with more than or equal to “x” carbonatoms and suitably less than 10 wt % and preferably less than 1 wt %hydrocarbon or olefin molecules, respectively, with x−1 carbon atoms.Lastly, the term “Cx− stream” can include a stream comprising a majorityof hydrocarbon or olefin molecules, respectively, with less than orequal to “x” carbon atoms and suitably less than 10 wt % and preferablyless than 1 wt % hydrocarbon or olefin molecules, respectively, with x+1carbon atoms.

As used herein, the term “zone” can refer to an area including one ormore equipment items and/or one or more sub-zones. Equipment items caninclude one or more reactors or reactor vessels, heaters, exchangers,pipes, pumps, compressors, controllers and columns. Additionally, anequipment item, such as a reactor, dryer, or vessel, can further includeone or more zones or sub-zones.

As used herein, the term “substantially” can mean an amount of at leastgenerally about 70%, preferably about 80%, and optimally about 90%, byweight, of a compound or class of compounds in a stream.

As used herein, the term “gasoline” can include hydrocarbons having aboiling point temperature in the range of about 25° to about 200° C. atatmospheric pressure.

As used herein, the term “diesel” or “distillate” can includehydrocarbons having a boiling point temperature in the range of about150° to about 400° C. and preferably about 200° to about 400° C.

As used herein, the term “vacuum gas oil” (VGO) can include hydrocarbonshaving a boiling temperature in the range of from 343° to 552° C.

As used herein, the term “vapor” can mean a gas or a dispersion that mayinclude or consist of one or more hydrocarbons.

As used herein, the term “overhead stream” can mean a stream withdrawnat or near a top of a vessel, such as a column.

As used herein, the term “bottom stream” can mean a stream withdrawn ator near a bottom of a vessel, such as a column.

As depicted, process flow lines in the figures can be referred tointerchangeably as, e.g., lines, pipes, feeds, gases, products,discharges, parts, portions, or streams.

As used herein, “bypassing” with respect to a vessel or zone means thata stream does not pass through the zone or vessel bypassed although itmay pass through a vessel or zone that is not designated as bypassed.

The term “communication” means that material flow is operativelypermitted between enumerated components.

The term “downstream communication” means that at least a portion ofmaterial flowing to the subject in downstream communication mayoperatively flow from the object with which it communicates.

The term “upstream communication” means that at least a portion of thematerial flowing from the subject in upstream communication mayoperatively flow to the object with which it communicates.

The term “direct communication” means that flow from the upstreamcomponent enters the downstream component without undergoing acompositional change due to physical fractionation or chemicalconversion.

The term “column” means a distillation column or columns for separatingone or more components of different volatilities. Unless otherwiseindicated, each column includes a condenser on an overhead of the columnto condense and reflux a portion of an overhead stream back to the topof the column and a reboiler at a bottom of the column to vaporize andsend a portion of a bottom stream back to the bottom of the column.Feeds to the columns may be preheated. The top pressure is the pressureof the overhead vapor at the outlet of the column. The bottomtemperature is the liquid bottom outlet temperature. Overhead lines andbottom lines refer to the net lines from the column downstream of thereflux or reboil to the column.

As used herein, the term “boiling point temperature” means atmosphericequivalent boiling point (AEBP) as calculated from the observed boilingtemperature and the distillation pressure, as calculated using theequations furnished in ASTM D1160 appendix A7 entitled “Practice forConverting Observed Vapor Temperatures to Atmospheric EquivalentTemperatures”.

As used herein, “taking a stream from” means that some or all of theoriginal stream is taken.

DETAILED DESCRIPTION

The present invention is an apparatus and process that can be used in afirst mode to primarily make gasoline, in a second mode to primarilymake diesel and in a third mode to make primarily propylene. Gasoline,diesel and propylene are produced in all three modes, but each modemaximizes the primary product intended. The apparatus and process may bedescribed with reference to four components shown in FIG. 1: a fluidcatalytic cracking (FCC) zone 20, an FCC recovery zone 100, apurification zone 110, an oligomerization zone 130, and anoligomerization recovery zone 200. Many configurations of the presentinvention are possible, but specific embodiments are presented herein byway of example. All other possible embodiments for carrying out thepresent invention are considered within the scope of the presentinvention.

The fluid catalytic cracking zone 20 may comprise a first FCC reactor22, a regenerator vessel 30, and an optional second FCC reactor 70.

A conventional FCC feedstock and higher boiling hydrocarbon feedstockare a suitable FCC hydrocarbon feed 24 to the first FCC reactor. Themost common of such conventional feedstocks is a VGO. Higher boilinghydrocarbon feedstocks to which this invention may be applied includeheavy bottom from crude oil, heavy bitumen crude oil, shale oil, tarsand extract, deasphalted residue, products from coal liquefaction,atmospheric and vacuum reduced crudes and mixtures thereof. The FCC feed24 may include a recycle stream 280 to be described later.

The first FCC reactor 22 may include a first reactor riser 26 and afirst reactor vessel 28. A regenerator catalyst pipe 32 deliversregenerated catalyst from the regenerator vessel 30 to the reactor riser26. A fluidization medium such as steam from a distributor 34 urges astream of regenerated catalyst upwardly through the first reactor riser26. At least one feed distributor injects the first hydrocarbon feed ina first hydrocarbon feed line 24, preferably with an inert atomizing gassuch as steam, across the flowing stream of catalyst particles todistribute hydrocarbon feed to the first reactor riser 26. Uponcontacting the hydrocarbon feed with catalyst in the first reactor riser26 the heavier hydrocarbon feed cracks to produce lighter gaseouscracked products while coke is deposited on the catalyst particles toproduce spent catalyst.

The resulting mixture of gaseous product hydrocarbons and spent catalystcontinues upwardly through the first reactor riser 26 and are receivedin the first reactor vessel 28 in which the spent catalyst and gaseousproduct are separated. Disengaging arms discharge the mixture of gas andcatalyst from a top of the first reactor riser 26 through outlet ports36 into a disengaging vessel 38 that effects partial separation of gasesfrom the catalyst. A transport conduit carries the hydrocarbon vapors,stripping media and entrained catalyst to one or more cyclones 42 in thefirst reactor vessel 28 which separates spent catalyst from thehydrocarbon gaseous product stream. Gas conduits deliver separatedhydrocarbon cracked gaseous streams from the cyclones 42 to a collectionplenum 44 for passage of a cracked product stream to a first crackedproduct line 46 via an outlet nozzle and eventually into the FCCrecovery zone 100 for product recovery.

Diplegs discharge catalyst from the cyclones 42 into a lower bed in thefirst reactor vessel 28. The catalyst with adsorbed or entrainedhydrocarbons may eventually pass from the lower bed into a strippingsection 48 across ports defined in a wall of the disengaging vessel 38.Catalyst separated in the disengaging vessel 38 may pass directly intothe stripping section 48 via a bed. A fluidizing distributor deliversinert fluidizing gas, typically steam, to the stripping section 48. Thestripping section 48 contains baffles or other equipment to promotecontacting between a stripping gas and the catalyst. The stripped spentcatalyst leaves the stripping section 48 of the disengaging vessel 38 ofthe first reactor vessel 28 stripped of hydrocarbons. A first portion ofthe spent catalyst, preferably stripped, leaves the disengaging vessel38 of the first reactor vessel 28 through a spent catalyst conduit 50and passes into the regenerator vessel 30. A second portion of the spentcatalyst may be recirculated in recycle conduit 52 from the disengagingvessel 38 back to a base of the first riser 26 at a rate regulated by aslide valve to recontact the feed without undergoing regeneration.

The first riser 26 can operate at any suitable temperature, andtypically operates at a temperature of about 150° to about 580° C. atthe riser outlet 36. The pressure of the first riser is from about 69 toabout 517 kPa (gauge) (10 to 75 psig) but typically less than about 275kPa (gauge) (40 psig). The catalyst-to-oil ratio, based on the weight ofcatalyst and feed hydrocarbons entering the riser, may range up to 30:1but is typically between about 4:1 and about 10:1. Steam may be passedinto the first reactor riser 26 and first reactor vessel 28 at a ratebetween about 2 and about 7 wt % for maximum gasoline production andabout 10 to about 15 wt % for maximum light olefin production. Theaverage residence time of catalyst in the riser may be less than about 5seconds.

The catalyst in the first reactor 22 can be a single catalyst or amixture of different catalysts. Usually, the catalyst includes twocatalysts, namely a first FCC catalyst, and a second FCC catalyst. Sucha catalyst mixture is disclosed in, e.g., U.S. Pat. No. 7,312,370 B2.Generally, the first FCC catalyst may include any of the well-knowncatalysts that are used in the art of FCC. Preferably, the first FCCcatalyst includes a large pore zeolite, such as a Y-type zeolite, anactive alumina material, a binder material, including either silica oralumina, and an inert filler such as kaolin.

Typically, the zeolites appropriate for the first FCC catalyst have alarge average pore size, usually with openings of greater than about 0.7nm in effective diameter defined by greater than about 10, and typicallyabout 12, member rings. Suitable large pore zeolite components mayinclude synthetic zeolites such as X and Y zeolites, mordenite andfaujasite. A portion of the first FCC catalyst, such as the zeoliteportion, can have any suitable amount of a rare earth metal or rareearth metal oxide.

The second FCC catalyst may include a medium or smaller pore zeolitecatalyst, such as exemplified by at least one of ZSM-5, ZSM-11, ZSM-12,ZSM-23, ZSM-35, ZSM-38, ZSM-48, and other similar materials. Othersuitable medium or smaller pore zeolites include ferrierite, anderionite. Preferably, the second component has the medium or smallerpore zeolite dispersed on a matrix including a binder material such assilica or alumina and an inert filler material such as kaolin. Thesecatalysts may have a crystalline zeolite content of about 10 to about 50wt % or more, and a matrix material content of about 50 to about 90 wt%. Catalysts containing at least about 40 wt % crystalline zeolitematerial are typical, and those with greater crystalline zeolite contentmay be used. Generally, medium and smaller pore zeolites arecharacterized by having an effective pore opening diameter of less thanor equal to about 0.7 nm and rings of about 10 or fewer members.Preferably, the second FCC catalyst component is an MFI zeolite having asilicon-to-aluminum ratio greater than about 15. In one exemplaryembodiment, the silicon-to-aluminum ratio can be about 15 to about 35.

The total catalyst mixture in the first reactor 22 may contain about 1to about 25 wt % of the second FCC catalyst, including a medium to smallpore crystalline zeolite, with greater than or equal to about 7 wt % ofthe second FCC catalyst being preferred. When the second FCC catalystcontains about 40 wt % crystalline zeolite with the balance being abinder material, an inert filler, such as kaolin, and optionally anactive alumina component, the catalyst mixture may contain about 0.4 toabout 10 wt % of the medium to small pore crystalline zeolite with apreferred content of at least about 2.8 wt %. The first FCC catalyst maycomprise the balance of the catalyst composition. The high concentrationof the medium or smaller pore zeolite as the second FCC catalyst of thecatalyst mixture can improve selectivity to light olefins. In oneexemplary embodiment, the second FCC catalyst can be a ZSM-5 zeolite andthe catalyst mixture can include about 0.4 to about 10 wt % ZSM-5zeolite excluding any other components, such as binder and/or filler.

The regenerator vessel 30 is in downstream communication with the firstreactor vessel 28. In the regenerator vessel 30, coke is combusted fromthe portion of spent catalyst delivered to the regenerator vessel 30 bycontact with an oxygen-containing gas such as air to regenerate thecatalyst. The spent catalyst conduit 50 feeds spent catalyst to theregenerator vessel 30. The spent catalyst from the first reactor vessel28 usually contains carbon in an amount of from 0.2 to 2 wt %, which ispresent in the form of coke. An oxygen-containing combustion gas,typically air, enters the lower chamber 54 of the regenerator vessel 30through a conduit and is distributed by a distributor 56. As thecombustion gas enters the lower chamber 54, it contacts spent catalystentering from spent catalyst conduit 50 and lifts the catalyst at asuperficial velocity of combustion gas in the lower chamber 54 ofperhaps at least 1.1 m/s (3.5 ft/s) under fast fluidized flowconditions. In an embodiment, the lower chamber 54 may have a catalystdensity of from 48 to 320 kg/m³ (3 to 20 lb/ft³) and a superficial gasvelocity of 1.1 to 2.2 m/s (3.5 to 7 ft/s). The oxygen in the combustiongas contacts the spent catalyst and combusts carbonaceous deposits fromthe catalyst to at least partially regenerate the catalyst and generateflue gas.

The mixture of catalyst and combustion gas in the lower chamber 54ascends through a frustoconical transition section to the transport,riser section of the lower chamber 54. The mixture of catalyst particlesand flue gas is discharged from an upper portion of the riser sectioninto the upper chamber 60. Substantially completely or partiallyregenerated catalyst may exit the top of the transport, riser section.Discharge is effected through a disengaging device 58 that separates amajority of the regenerated catalyst from the flue gas. The catalyst andgas exit downwardly from the disengaging device 58. The sudden loss ofmomentum and downward flow reversal cause a majority of the heaviercatalyst to fall to the dense catalyst bed and the lighter flue gas anda minor portion of the catalyst still entrained therein to ascendupwardly in the upper chamber 60. Cyclones 62 further separate catalystfrom ascending gas and deposits catalyst through dip legs into a densecatalyst bed. Flue gas exits the cyclones 62 through a gas conduit andcollects in a plenum 64 for passage to an outlet nozzle of regeneratorvessel 30. Catalyst densities in the dense catalyst bed are typicallykept within a range of from about 640 to about 960 kg/m³ (40 to 60lb/ft³).

The regenerator vessel 30 typically has a temperature of about 594° toabout 704° C. (1100° to 1300° F.) in the lower chamber 54 and about 649°to about 760° C. (1200° to 1400° F.) in the upper chamber 60.Regenerated catalyst from dense catalyst bed is transported throughregenerated catalyst pipe 32 from the regenerator vessel 30 back to thefirst reactor riser 26 through the control valve where it again contactsthe first feed in line 24 as the FCC process continues. The firstcracked product stream in the first cracked product line 46 from thefirst reactor 22, relatively free of catalyst particles and includingthe stripping fluid, exit the first reactor vessel 28 through an outletnozzle. The first cracked products stream in the line 46 may besubjected to additional treatment to remove fine catalyst particles orto further prepare the stream prior to fractionation. The line 46transfers the first cracked products stream to the FCC recovery zone100, which is in downstream communication with the FCC zone 20. The FCCrecovery zone 100 typically includes a main fractionation column and agas recovery section. The FCC recovery zone can include manyfractionation columns and other separation equipment. The FCC recoveryzone 100 can recover a propylene product stream in propylene line 102, agasoline stream in gasoline line 104, a light olefin stream in lightolefin line 106 and an LCO stream in LCO line 107 among others from thecracked product stream in first cracked product line 46. The lightolefin stream in light olefin line 106 comprises an oligomerization feedstream having C₄ hydrocarbons including C₄ olefins and perhaps having C₅hydrocarbons including C₅ olefins.

An FCC recycle stream in recycle line 280 delivers an FCC recycle streamto the FCC zone 20. The FCC recycle stream is directed into a first FCCrecycle line 202 with the control valve 202′ thereon opened. In anaspect, the FCC recycle stream may be directed into an optional secondFCC recycle line 204 with the control valve 204′ thereon opened. Thefirst FCC recycle line 202 delivers the first FCC recycle stream to thefirst FCC reactor 22 in an aspect to the riser 26 at an elevation abovethe first hydrocarbon feed in line 24. The second FCC recycle line 204delivers the second FCC recycle stream to the second FCC reactor 70.Typically, both control valves 202′ and 204′ will not be opened at thesame time, so the FCC recycle stream goes through only one of the firstFCC recycle line 202 and the second FCC recycle line 204. However, feedthrough both is contemplated.

The second FCC recycle stream may be fed to the second FCC reactor 70 inthe second FCC recycle line 204 via feed distributor 72. The second FCCreactor 70 may include a second riser 74. The second FCC recycle streamis contacted with catalyst delivered to the second riser 74 by acatalyst return pipe 76 to produce cracked upgraded products. Thecatalyst may be fluidized by inert gas such as steam from distributor78. Generally, the second FCC reactor 70 may operate under conditions toconvert the second FCC recycle stream to second cracked products such asethylene and propylene. A second reactor vessel 80 is in downstreamcommunication with the second riser 74 for receiving second crackedproducts and catalyst from the second riser. The mixture of gaseous,second cracked product hydrocarbons and catalyst continues upwardlythrough the second reactor riser 74 and is received in the secondreactor vessel 80 in which the catalyst and gaseous, second crackedproducts are separated. A pair of disengaging arms may tangentially andhorizontally discharge the mixture of gas and catalyst from a top of thesecond reactor riser 74 through one or more outlet ports 82 (only one isshown) into the second reactor vessel 80 that effects partial separationof gases from the catalyst. The catalyst can drop to a dense catalystbed within the second reactor vessel 80. Cyclones 84 in the secondreactor vessel 80 may further separate catalyst from second crackedproducts. Afterwards, a second cracked product stream can be removedfrom the second FCC reactor 70 through an outlet in a second crackedproduct line 86 in downstream communication with the second reactorriser 74. The second cracked product stream in line 86 is fed to the FCCrecovery zone 100, preferably separately from the first cracked productsto undergo separation and recovery of ethylene and propylene. Separatedcatalyst may be recycled via a recycle catalyst pipe 76 from the secondreactor vessel 80 regulated by a control valve back to the secondreactor riser 74 to be contacted with the second FCC recycle stream.

In some embodiments, the second FCC reactor 70 can contain a mixture ofthe first and second FCC catalysts as described above for the first FCCreactor 22. In one preferred embodiment, the second FCC reactor 70 cancontain less than about 20 wt %, preferably less than about 5 wt % ofthe first FCC catalyst and at least 20 wt % of the second FCC catalyst.In another preferred embodiment, the second FCC reactor 70 can containonly the second FCC catalyst, preferably a ZSM-5 zeolite.

The second FCC reactor 70 is in downstream communication with theregenerator vessel 30 and receives regenerated catalyst therefrom inline 88. In an embodiment, the first FCC reactor 22 and the second FCCreactor 70 both share the same regenerator vessel 30. Line 90 carriesspent catalyst from the second reactor vessel 80 to the lower chamber 54of the regenerator vessel 30. The catalyst regenerator is in downstreamcommunication with the second FCC reactor 70 via line 90.

The same catalyst composition may be used in both reactors 22, 70.However, if a higher proportion of the second FCC catalyst of small tomedium pore zeolite is desired in the second FCC reactor 70 than thefirst FCC catalyst of large pore zeolite, replacement catalyst added tothe second FCC reactor 70 may comprise a higher proportion of the secondFCC catalyst. Because the second FCC catalyst does not lose activity asquickly as the first FCC catalyst, less of the second catalyst inventorymust be forwarded to the catalyst regenerator 30 in line 90 from thesecond reactor vessel 80, but more catalyst inventory may be recycled tothe riser 74 in return conduit 76 without regeneration to maintain ahigh level of the second FCC catalyst in the second reactor 70.

The second reactor riser 74 can operate in any suitable condition, suchas a temperature of about 425° to about 705° C., preferably atemperature of about 550° to about 600° C., and a pressure of about 140to about 400 kPa, preferably a pressure of about 170 to about 250 kPa.Typically, the residence time of the second reactor riser 74 can be lessthan about 3 seconds and preferably is than about 1 second. Exemplaryrisers and operating conditions are disclosed in, e.g., US 2008/0035527A1 and U.S. Pat. No. 7,261,807 B2.

Before cracked products can be fed to the oligomerization zone 130, thelight olefin stream in light olefin line 106 may require purification.Many impurities in the light olefin stream in light olefin line 106 canpoison an oligomerization catalyst. Carbon dioxide and ammonia canattack acid sites on the catalyst. Sulfur containing compounds,oxygenates, and nitriles can harm oligomerization catalyst. Acetylenesand diolefins can polymerize and produce gums on the catalyst orequipment. Consequently, the light olefin stream which comprises theoligomerization feed stream in light olefin line 106 may be purified inan optional purification zone 110.

The light olefin stream in light olefin line 106 may be introduced intoan optional mercaptan extraction unit 112 to remove mercaptans to lowerconcentrations. In the mercaptan extraction unit 112, the light olefinfeed may be prewashed in an optional prewash vessel containing aqueousalkali to convert any hydrogen sulfide to sulfide salt which is solublein the aqueous alkaline stream. The light olefin stream, now depleted ofany hydrogen sulfide, is contacted with a more concentrated aqueousalkali stream in an extractor vessel. Mercaptans in the light olefinstream react with the alkali to yield mercaptides. An extracted lightolefin stream lean in mercaptans passes overhead from the extractioncolumn and may be mixed with a solvent that removes COS in route to anoptional COS solvent settler. COS is removed with the solvent from thebottom of the settler, while the overhead light olefin stream may be fedto an optional water wash vessel to remove remaining alkali and producea sulfur depleted light olefin stream in line 114. The mercaptide richalkali from the extractor vessel receives an injection of air and acatalyst such as phthalocyanine as it passes from the extractor vesselto an oxidation vessel for regeneration. Oxidizing the mercaptides todisulfides using a catalyst regenerates the alkaline solution. Adisulfide separator receives the disulfide rich alkaline from theoxidation vessel. The disulfide separator vents excess air and decantsdisulfides from the alkaline solution before the regenerated alkaline isdrained, washed with oil to remove remaining disulfides and returned tothe extractor vessel. Further removal of disulfides from the regeneratedalkaline stream is also contemplated. The disulfides are run through asand filter and removed from the process. For more information onmercaptan extraction, reference may be made to U.S. Pat. No. 7,326,333B2.

In order to prevent polymerization and gumming in the oligomerizationreactor that can inhibit equipment and catalyst performance, it isdesired to minimize diolefins and acetylenes in the light olefin feed inline 114. Diolefin conversion to monoolefin hydrocarbons may beaccomplished by selectively hydrogenating the sulfur depleted streamwith a conventional selective hydrogenation reactor 116. Hydrogen may beadded to the purified light olefin stream in line 118.

The selective hydrogenation catalyst can comprise an alumina supportmaterial preferably having a total surface area greater than 150 m²/g,with most of the total pore volume of the catalyst provided by poreswith average diameters of greater than 600 angstroms, and containingsurface deposits of about 1.0 to 25.0 wt % nickel and about 0.1 to 1.0wt % sulfur such as disclosed in U.S. Pat. No. 4,695,560. Spheres havinga diameter between about 0.4 and 6.4 mm ( 1/64 and ¼ inch) can be madeby oil dropping a gelled alumina sol. The alumina sol may be formed bydigesting aluminum metal with an aqueous solution of approximately 12 wt% hydrogen chloride to produce an aluminum chloride sol. The nickelcomponent may be added to the catalyst during the sphere formation or byimmersing calcined alumina spheres in an aqueous solution of a nickelcompound followed by drying, calcining, purging and reducing. The nickelcontaining alumina spheres may then be sulfided. A palladium catalystmay also be used as the selective hydrogenation catalyst.

The selective hydrogenation process is normally performed at relativelymild hydrogenation conditions. These conditions will normally result inthe hydrocarbons being present as liquid phase materials. The reactantswill normally be maintained under the minimum pressure sufficient tomaintain the reactants as liquid phase hydrocarbons which allow thehydrogen to dissolve into the light olefin feed. A broad range ofsuitable operating pressures therefore extends from about 276 (40 psig)to about 5516 kPa gauge (800 psig). A relatively moderate temperaturebetween about 25° C. (77° F.) and about 350° C. (662° F.) should beemployed. The liquid hourly space velocity of the reactants through theselective hydrogenation catalyst should be above 1.0 hr⁻¹. Preferably,it is between 5.0 and 35.0 hr⁻¹. The ratio of hydrogen to diolefinichydrocarbons may be maintained between 0.75:1 and 1.8:1. Thehydrogenation reactor is preferably a cylindrical fixed bed of catalystthrough which the reactants move in a vertical direction.

A purified light olefin stream depleted of sulfur containing compounds,diolefins and acetylenes exits the selective hydrogenation reactor 116in line 120. The optionally sulfur and diolefin depleted light olefinstream in line 120 may be introduced into an optional nitrile removalunit (NRU) such as a water wash unit 122 to reduce the concentration ofoxygenates and nitriles in the light olefin stream in line 120. Water isintroduced to the water wash unit in line 124. An oxygenate andnitrile-rich aqueous stream in line 126 leaves the water wash unit 122and may be further processed. A drier may follow the water wash unit122. Other NRU's may be used in place of the water wash unit. A NRU canconsist of a group of regenerable beds that adsorb the nitriles andother nitrogen components from the diolefin depleted light olefinstream. Examples of NRU's can be found in U.S. Pat. No. 4,831,206, U.S.Pat. No. 5,120,881 and U.S. Pat. No. 5,271,835.

A purified light olefin oligomerization feed stream perhaps depleted ofsulfur containing compounds, diolefins and/or oxygenates and nitriles isprovided in oligomerization feed stream line 128. The light olefinoligomerization feed stream in line 128 may be obtained from the crackedproduct stream in lines 46 and/or 86, so it may be in downstreamcommunication with the FCC zone 20. The oligomerization feed stream neednot be obtained from a cracked FCC product stream but may come fromanother source. The selective hydrogenation reactor 116 is in upstreamcommunication with the oligomerization feed stream line 128. Theoligomerization feed stream may comprise C₄ hydrocarbons such asbutenes, i.e., C₄ olefins, and butanes. Butenes include normal butenesand isobutene. The oligomerization feed stream in oligomerization feedstream line 128 may comprise C₅ hydrocarbons such as pentenes, i.e., C₅olefins, and pentanes. Pentenes include normal pentenes and isopentenes.Typically, the oligomerization feed stream will comprise about 20 toabout 80 wt % olefins and suitably about 40 to about 75 wt % olefins. Inan aspect, about 55 to about 75 wt % of the olefins may be butenes andabout 25 to about 45 wt % of the olefins may be pentenes. As much as 10wt %, suitably 20 wt %, typically 25 wt % and most typically 30 wt % ofthe oligomerization feed may be C₅ olefins.

The oligomerization feed line 128 feeds the oligomerization feed streamto an oligomerization zone 130 which may be in downstream communicationwith the FCC recovery zone 100. The oligomerization feed stream inoligomerization feed line 128 may be mixed with recycle streams fromline 226 or 246 prior to entering the oligomerization zone 130 toprovide an oligomerization feed stream in an oligomerization feedconduit 132. An oligomerization reactor zone 140 is in downstreamcommunication with the oligomerization feed conduit 132.

In an aspect, an oligomerate return stream in oligomerate return line231 to be described hereinafter may be mixed with the oligomerizationfeed stream in oligomerization feed conduit 132 in a first mixedoligomerization feed line 133. The oligomerization feed stream in line133 may comprise about 10 to about 50 wt % olefins and suitably about 25to about 40 wt % olefins if the oligomerate return stream fromoligomerate return line 231 is mixed with the oligomerization feedstream. Accordingly, the oligomerization feed stream may comprise nomore than about 38 wt % butene and in another aspect, theoligomerization feed stream may comprise no more than about 23 wt %pentene. The oligomerization feed stream to the oligomerization zone 130in mixed oligomerization feed conduit 133 may comprise at least about 10wt % butene, at least about 5 wt % pentene and preferably no more thanabout 1 wt % hexene. In a further aspect, the oligomerization feedstream may comprise no more than about 0.1 wt % hexene and no more thanabout 0.1 wt % propylene. At least about 40 wt % of the butene in theoligomerization feed stream may be normal butene. In an aspect, it maybe that no more than about 70 wt % of the oligomerization feed stream isnormal butene. At least about 40 wt % of the pentene in theoligomerization feed stream may be normal pentene. In an aspect, no morethan about 70 wt % of the oligomerization feed stream in the mixedoligomerization feed conduit 133 may be normal pentene.

The oligomerization reactor zone 140 comprises a first oligomerizationreactor 138. The first oligomerization reactor may be preceded by anoptional guard bed for removing catalyst poisons that is not shown. Thefirst oligomerization reactor 138 contains the oligomerization catalyst.An oligomerization feed stream may be preheated before entering thefirst oligomerization reactor 138 in an oligomerization reactor zone140. The first oligomerization reactor 138 may contain a first catalystbed 142 of oligomerization catalyst. The first oligomerization reactor138 may be an upflow reactor to provide a uniform feed front through thecatalyst bed, but other flow arrangements are contemplated. In anaspect, the first oligomerization reactor 138 may contain an additionalbed or beds 144 of oligomerization catalyst. C₄ olefins in theoligomerization feed stream oligomerize over the oligomerizationcatalyst to provide an oligomerate comprising C₄ olefin dimers andtrimers. C₅ olefins that may be present in the oligomerization feedstream oligomerize over the oligomerization catalyst to provide anoligomerate comprising C₅ olefin dimers and trimers and co-oligomerizewith C₄ olefins to make C₉ olefins. The oligomerization produces otheroligomers with additional carbon numbers.

We have found that adding C₅ olefins to the feed to the oligomerizationreactor reduces oligomerization to heavier, distillate range material.This is counterintuitive since one may expect heavier C₅ olefins to leadto the formation of more distillate range material. However, when C₅olefins dimerize with themselves or co-dimerize with C₄ olefins, the C₉olefins and C₁₀ olefins produced do not continue to oligomerize asquickly as C₈ olefins produced from C₄ olefin dimerization. Thus, theamount of net gasoline produced can be increased. In addition, theresulting C₉ olefins and C₁₀ olefins in the product have a very highoctane value.

Oligomerization effluent from the first bed 142 may optionally bequenched with a liquid such as recycled oligomerate before entering theadditional bed 144, and/or oligomerization effluent from the additionalbed 144 of oligomerization catalyst may also be quenched with a liquidsuch as recycled oligomerate to avoid excessive temperature rise. Theliquid oligomerate may also comprise oligomerized olefins that can reactwith the C₄ olefins and C₅ olefins in the feed and other oligomerizedolefins if present to make diesel range olefins. Oligomerized product,also known as oligomerate, exits the first oligomerization reactor 138in line 146.

In an aspect, the oligomerization reactor zone may include one or moreadditional oligomerization reactors 150. The oligomerization effluentmay be heated and fed to the optional additional oligomerization reactor150. It is contemplated that the first oligomerization reactor 138 andthe additional oligomerization reactor 150 may be operated in a swingbed fashion to take one reactor offline for maintenance or catalystregeneration or replacement while the other reactor stays online. In anaspect, the additional oligomerization reactor 150 may contain a firstbed 152 of oligomerization catalyst. The additional oligomerizationreactor 150 may also be an upflow reactor to provide a uniform feedfront through the catalyst bed, but other flow arrangements arecontemplated. In an aspect, the additional oligomerization reactor 150may contain an additional bed or beds 154 of oligomerization catalyst.Remaining C₄ olefins in the oligomerization feed stream oligomerize overthe oligomerization catalyst to provide an oligomerate comprising C₄olefin dimers and trimers. Remaining C₅ olefins, if present in theoligomerization feed stream, oligomerize over the oligomerizationcatalyst to provide an oligomerate comprising C₅ olefin dimers andtrimers and co-oligomerize with C₄ olefins to make C₉ olefins. Over 90wt % of the C₄ olefins in the oligomerization feed stream canoligomerize in the oligomerization reactor zone 140. Over 90 wt % of theC₅ olefins in the oligomerization feed stream can oligomerize in theoligomerization reactor zone 140. If more than one oligomerizationreactor is used, conversion is achieved over all of the oligomerizationreactors 138, 150 in the oligomerization reactor zone 140.

Oligomerization effluent from the first bed 152 may be quenched with aliquid such as recycled oligomerate before entering the additional bed154, and/or oligomerization effluent from the additional bed 154 ofoligomerization catalyst may also be quenched with a liquid such asrecycled oligomerate to avoid excessive temperature rise. The recycledoligomerate may also comprise oligomerized olefins that can react withthe C₄ olefins and C₅ olefins in the feed and other oligomerized olefinsto increase production of diesel range olefins.

An oligomerate conduit 156, in communication with the oligomerizationreactor zone 140, withdraws an oligomerate stream from theoligomerization reactor zone 140. The oligomerate conduit 156 may be indownstream communication with the first oligomerization reactor 138 andthe additional oligomerization reactor 150.

The oligomerization reactor zone 140 may contain an oligomerizationcatalyst. The oligomerization catalyst may comprise a zeolitic catalyst.The zeolite may comprise between 5 and 95 wt % of the catalyst. Suitablezeolites include zeolites having a structure from one of the followingclasses: MFI, MEL, SFV, SVR, ITH, IMF, TUN, FER, EUO, BEA, FAU, BPH,MEI, MSE, MWW, UZM-8, MOR, OFF, MTW, TON, MTT, AFO, ATO, and AEL. Thesethree-letter codes for structure types are assigned and maintained bythe International Zeolite Association Structure Commission in the Atlasof Zeolite Framework Types, which is athttp://www.iza-structure.org/databases/. In a preferred aspect, theoligomerization catalyst may comprise a zeolite with a framework havinga ten-ring pore structure. Examples of suitable zeolites having aten-ring pore structure include those comprising TON, MTT, MFI, MEL,AFO, AEL, EUO and FER. In a further preferred aspect, theoligomerization catalyst comprising a zeolite having a ten-ring porestructure may comprise a uni-dimensional pore structure. Auni-dimensional pore structure indicates zeolites containingnon-intersecting pores that are substantially parallel to one of theaxes of the crystal. The pores preferably extend through the zeolitecrystal. Suitable examples of zeolites having a ten-ring uni-dimensionalpore structure may include MTT. In a further aspect, the oligomerizationcatalyst comprises an MTT zeolite.

The oligomerization catalyst may be formed by combining the zeolite witha binder, and then forming the catalyst into pellets. The pellets mayoptionally be treated with a phosphoric reagent to create a zeolitehaving a phosphorous component between 0.5 and 15 wt % of the treatedcatalyst. The binder is used to confer hardness and strength on thecatalyst. Binders include alumina, aluminum phosphate, silica,silica-alumina, zirconia, titania and combinations of these metaloxides, and other refractory oxides, and clays such as montmorillonite,kaolin, palygorskite, smectite and attapulgite. A preferred binder is analuminum-based binder, such as alumina, aluminum phosphate,silica-alumina and clays.

One of the components of the catalyst binder utilized in the presentinvention is alumina. The alumina source may be any of the varioushydrous aluminum oxides or alumina gels such as alpha-aluminamonohydrate of the boehmite or pseudo-boehmite structure, alpha-aluminatrihydrate of the gibbsite structure, beta-alumina trihydrate of thebayerite structure, and the like. A suitable alumina is available fromUOP LLC under the trademark Versal. A preferred alumina is availablefrom Sasol North America Alumina Product Group under the trademarkCatapal. This material is an extremely high purity alpha-aluminamonohydrate (pseudo-boehmite) which after calcination at a hightemperature has been shown to yield a high purity gamma-alumina.

A suitable oligomerization catalyst is prepared by mixing proportionatevolumes of zeolite and alumina to achieve the desired zeolite-to-aluminaratio. In an embodiment, about 5 to about 80, typically about 10 toabout 60, suitably about 15 to about 40 and preferably about 20 to about30 wt % MTT zeolite and the balance alumina powder will provide asuitably supported catalyst. A silica support is also contemplated.

Monoprotic acid such as nitric acid or formic acid may be added to themixture in aqueous solution to peptize the alumina in the binder.Additional water may be added to the mixture to provide sufficientwetness to constitute a dough with sufficient consistency to be extrudedor spray dried. Extrusion aids such as cellulose ether powders can alsobe added. A preferred extrusion aid is available from The Dow ChemicalCompany under the trademark Methocel.

The paste or dough may be prepared in the form of shaped particulates,with the preferred method being to extrude the dough through a diehaving openings therein of desired size and shape, after which theextruded matter is broken into extrudates of desired length and dried. Afurther step of calcination may be employed to give added strength tothe extrudate. Generally, calcination is conducted in a stream of air ata temperature from about 260° C. (500° F.) to about 815° C. (1500° F.).The MTT catalyst is not selectivated to neutralize surface acid sitessuch as with an amine.

The extruded particles may have any suitable cross-sectional shape,i.e., symmetrical or asymmetrical, but most often have a symmetricalcross-sectional shape, preferably a spherical, cylindrical or polylobalshape. The cross-sectional diameter of the particles may be as small as40 μm; however, it is usually about 0.635 mm (0.25 inch) to about 12.7mm (0.5 inch), preferably about 0.79 mm ( 1/32 inch) to about 6.35 mm(0.25 inch), and most preferably about 0.06 mm ( 1/24 inch) to about4.23 mm (⅙ inch).

In an embodiment, the oligomerization catalyst may be a solid phosphoricacid catalyst (SPA). The SPA catalyst refers to a solid catalyst thatcontains as a principal ingredient an acid of phosphorous such asortho-, pyro- or tetraphosphoric acid. SPA catalyst is normally formedby mixing the acid of phosphorous with a siliceous solid carrier to forma wet paste. This paste may be calcined and then crushed to yieldcatalyst particles or the paste may be extruded or pelleted prior tocalcining to produce more uniform catalyst particles. The carrier ispreferably a naturally occurring porous silica-containing material suchas kieselguhr, kaolin, infusorial earth and diatomaceous earth. A minoramount of various additives such as mineral talc, fuller's earth andiron compounds including iron oxide may be added to the carrier toincrease its strength and hardness. The combination of the carrier andthe additives preferably comprises about 15-30 wt % of the catalyst,with the remainder being the phosphoric acid. The additive may compriseabout 3-20 wt % of the total carrier material. Variations from thiscomposition such as a lower phosphoric acid content are possible.Further details as to the composition and production of SPA catalystsmay be obtained from U.S. Pat. No. 3,050,472, U.S. Pat. No. 3,050,473and U.S. Pat. No. 3,132,109. Feed to the oligomerization reactor zone140 containing SPA catalyst should be kept dry except in an initialstart-up phase.

The oligomerization reaction conditions in the oligomerization reactors138, 150 in the oligomerization reactor zone 140 are set to keep thereactant fluids in the liquid phase. With liquid oligomerate recycle,lower pressures are necessary to maintain liquid phase. Operatingpressures include between about 2.1 MPa (300 psia) and about 10.5 MPa(1520 psia), suitably at a pressure between about 2.1 MPa (300 psia) andabout 6.9 MPa (1000 psia) and preferably at a pressure between about 2.8MPa (400 psia) and about 4.1 MPa (600 psia). Lower pressures may besuitable if the reaction is kept in the liquid phase.

For the zeolite catalyst, the temperature of the oligomerization reactorzone 140 expressed in terms of a maximum bed temperature is in a rangebetween about 150° C. and about 300° C. If diesel oligomerate isdesired, the maximum bed temperature should between about 200° C. andabout 250° C. and preferably between about 215° or about 225° C. andabout 245° C. or between about 220° and about 240° C. The space velocityshould be between about 0.5 and about 5 hr⁻¹.

For the SPA catalyst, the oligomerization temperature in theoligomerization reactor zone 140 should be in a range between about 100°C. and about 250° C. and suitably between about 150° C. and about 200°C. The liquid hourly space velocity (LHSV) should be between about 0.5and about 5 hr⁻¹.

Across a single bed of oligomerization catalyst, the exothermic reactionwill cause the temperature to rise. Consequently, the oligomerizationreactor should be operated to allow the temperature at the outlet to beover about 25° C. greater than the temperature at the inlet.

The oligomerization reactor zone 140 with the oligomerization catalystcan be run in high conversion mode of greater than 95% conversion offeed olefins to produce a high quality diesel product and gasolineproduct. Normal butene conversion can exceed about 80%. Additionally,normal pentene conversion can exceed about 80%.

We have found that when C₅ olefins are present in the oligomerizationfeed stream, they dimerize or co-dimerize with other olefins, but tendto mitigate further oligomerization over the zeolite with a 10-ringuni-dimensional pore structure. Best mitigation of furtheroligomerization occurs when the C₅ olefins comprise between 15 or 30 and70 wt % and preferably between 20 or 40 and 50 or 60 wt % of the olefinsin the oligomerization feed. Consequently, the oligomerate stream inoligomerate conduit 156 may comprise less than about 80 wt % C₉+hydrocarbons when C₅ olefins are present in the oligomerization feed atthese proportions. Moreover, said oligomerate may comprise less thanabout 60 wt % C₁₂+ hydrocarbons when C₅ olefins are present in theoligomerization feed at these proportions. Furthermore, the net gasolineyield may be at least about 40 wt % when C₅ olefins are present in theoligomerization feed.

If diesel is desired, however, the oligomerization zone with theoligomerization catalyst can be operated to oligomerize light olefins;i.e., C₄ olefins, to distillate-range material by over 70 wt % yield perpass through the oligomerization reactor zone 140. In an aspect, atleast about 70 wt % of the olefins in the oligomerization feed convertto C₉+ product oligomers boiling above about 150° C. (302° F.) cut pointin a single pass through the oligomerization zone. The C₁₂+ oligomerfrom the oligomerization zone boiling above about 200° C. (392° F.) mayhave a cetane of at least 30 and preferably at least 40.

The composition of the oligomerate in oligomerate line 156 may be anolefinic hydrocarbon composition having C₈ olefins. The olefinichydrocarbon composition may include gasoline. In an embodiment, thecomposition may be moderate in Type 2 disubstituted olefins and high inType 4 trisubstituted olefins. In an aspect, the oligomerate compositionmay have a ratio of Type 2 disubstituted C₈ olefins to Type 1monosubstituted C₈ olefins of greater than about 2. In a further aspect,a fraction of Type 2 disubstituted C₈ olefins in the total C₈ olefins inthe oligomerate may be no less than about 7 and less than about 18 wt %.In an even further aspect, a fraction of Type 4 trisubstituted C₈olefins in the total C₈ olefins may be no less than about 40 wt %. In astill further aspect, an average branch per C₈ hydrocarbon molecule inthe oligomerate may be less than 2. The oligomerate may have a cetane ofgreater than 30 and preferably greater than 40. The oligomerate may havea density of less than 0.83 kg/m³, preferably less than 0.81 kg/m³, lessthan 20 ppmw sulfur or less than 1 vol % aromatics. The oligomerate mayhave a ratio of trimethyl pentene to the total C₈ olefins of no morethan 50 and preferably no more than 40.

An oligomerization recovery zone 200 is in downstream communication withthe oligomerization zone 130 and the oligomerate conduit 156. Theoligomerate conduit 156 removes the oligomerate stream from theoligomerization zone 130.

The oligomerization recovery zone 200 may include a debutanizer column210 which separates the oligomerate stream between vapor and liquid intoa first vaporous oligomerate overhead light stream comprising C₄ olefinsand hydrocarbons in a first overhead line 212 and a first liquidoligomerate bottom stream comprising C₅+ olefins and hydrocarbons in afirst bottom line 214. When maximum production of distillate is desired,either to obtain diesel product or to recrack the diesel in the FCC zone20 to make more propylene, the overhead pressure in the debutanizercolumn 210 may be between about 300 and about 350 kPa (gauge) and thebottom temperature may be between about 250° and about 300° C. Whenmaximum production of gasoline is desired, the overhead pressure in thedebutanizer column 210 may be between about 525 and about 575 kPa(gauge) and the bottom temperature may be between about 90° and about140° C. The first vaporous oligomerate overhead light stream comprisingC₄ hydrocarbons may be rejected from the process and subjected tofurther processing to recover useful components.

It is desired to maintain liquid phase in the oligomerization reactors.This is typically achieved by saturating product olefins and recyclingthem to the oligomerization reactor as a liquid. However, if olefinicproduct is being recycled to either the FCC zone 20 or theoligomerization zone 130, saturating olefins would inactivate therecycle feed. The oligomerization zone 130 can only further oligomerizeolefinic recycle and the FCC zone 20 prefers olefinic feed to be furthercracked to form propylene.

Liquid phase may be maintained in the oligomerization zone 130 byincorporating into the feed a C₅ stream from the oligomerizationrecovery zone 200. The oligomerization recovery zone 200 may include adepentanizer column 220 to which the first liquid oligomerate bottomstream comprising C₅+ hydrocarbons may be fed in line 214. Thedepentanizer column 220 may separate the first liquid oligomerate bottomstream between vapor and liquid into an intermediate stream comprisingC₅ olefins and hydrocarbons in an intermediate line 222 and a liquidoligomerate bottom product stream comprising C₆+ olefins in a bottomproduct line 224. When maximum production of distillate is desired,either to obtain diesel product or to recrack the diesel in the FCC zone20 to make more propylene, the overhead pressure in the depentanizercolumn 220 may be between about 10 and about 60 kPa (gauge) and thebottom temperature may be between about 225° and about 275° C. Whenmaximum production of gasoline is desired, the overhead pressure in thedepentanizer column 220 may be between about 250 and about 300 kPa(gauge) and the bottom temperature may be between about 150° and about200° C.

The intermediate stream in intermediate line 222 may comprise at least30 wt % and suitably at least 40 wt % C₅ hydrocarbons which can then actas a solvent in the oligomerization reactor zone 140 to maintain liquidphase therein. The overhead intermediate stream comprising C₅hydrocarbons should have less than 10 wt % C₄ or C₆ hydrocarbons andpreferably less than 1 wt % C₄ or C₆ hydrocarbons.

The intermediate stream may be condensed and recycled to theoligomerization zone 130 as a first intermediate recycle stream in anintermediate recycle line 226 to maintain the liquid phase in theoligomerization reactors 138, 150 operating in the oligomerization zone130. The C₅ overhead stream may comprise C₅ olefins that can oligomerizein the oligomerization zone. The C₅ hydrocarbon presence in theoligomerization zone maintains the oligomerization reactors at liquidphase conditions. The pentanes are easily separated from the heavierolefinic product such as in the depentanizer column 220. The pentanerecycled to the oligomerization zone also dilutes the feed olefins tohelp limit the temperature rise within the reactor due to theexothermicity of the reaction.

We have found that dimethyl sulfide boils with the C₅ hydrocarbons anddeactivates the unidimensional, 10-ring pore structured zeolite whichmay be the oligomerization catalyst. The mercaptan extraction unit 112does not remove sufficient dimethyl sulfide to avoid deactivating theoligomerization catalyst. Consequently, recycle of C₅ hydrocarbons tothe oligomerization reactor zone 140 with oligomerization catalystshould be avoided by keeping valve 226′ shut unless dimethyl sulfide canbe successfully removed from the oligomerate stream or theoligomerization catalyst is not a unidimensional, 10-ring porestructured zeolite. However, the dimethyl sulfide does not substantiallyharm the solid phosphoric acid catalyst, so recycle of C₅ hydrocarbonsto the oligomerization reactor zone 140 is suitable if SPA is theoligomerization catalyst.

In an aspect, the intermediate stream in the intermediate line 222comprising C₅ hydrocarbons may be split into a purge stream in purgeline 228 and the first intermediate recycle stream comprising C₅hydrocarbons in the first intermediate recycle line 226. In an aspect,the first intermediate recycle stream in first intermediate recycle line226 taken from the intermediate stream in intermediate line 222 isrecycled to the oligomerization zone 130 downstream of the selectivehydrogenation reactor 116. The intermediate stream in intermediate line222 and the first intermediate recycle stream in intermediate recycleline 226 should be understood to be condensed overhead streams. Theintermediate recycle stream comprising C₅ hydrocarbons may be recycledto the oligomerization zone 130 at a mass flow rate which is at least asgreat as and suitably no greater than three times the mass flow rate ofthe oligomerization feed stream in the oligomerization feed line 128 fedto said oligomerization zone 130 absent the addition of any recyclestreams such as in line 246 to be explained hereinafter. The recyclerate may be adjusted as necessary to maintain liquid phase in theoligomerization reactors and to control temperature rise, and tomaximize selectivity to gasoline range oligomer products.

The purge stream comprising C₅ hydrocarbons taken from the intermediatestream may be purged from the process in line 228 to avoid C₅ build upin the process. The purge stream comprising C₅ hydrocarbons in line 228may be subjected to further processing to recover useful components orbe blended in the gasoline pool.

Three streams may be taken from the liquid oligomerate bottom productstream in bottom product line 224. A recycle oligomerate product streamcomprising C₆+ olefins in recycle oligomerate product line 230 may betaken from the liquid oligomerate bottom product stream in bottomproduct line 224. The liquid oligomerate bottom product stream in thebottom product line 224 may have the same composition as described forthe C₈ olefins of the oligomerate in oligomerate line 156. The liquidoligomerate bottom product stream in the bottom product line 224 mayhave greater than 10 wt % C₁₀ isoolefins. Flow through recycle line 230can be regulated by control valve 230′. In another aspect, a distillateseparator feed stream in distillate feed line 232 may be taken from theliquid oligomerate bottom product stream in the bottom product line 224.Flow through distillate feed line 232 can be regulated by control valve232′. In a further aspect, a gasoline oligomerate product stream in agasoline oligomerate product line 250 can be taken from the liquidoligomerate bottom product stream in bottom product line 224. Flowthrough gasoline oligomerate product line 250 can be regulated bycontrol valve 250′. Flow through recycle oligomerate product line 230,distillate feed line 232 and gasoline oligomerate product line 250 canbe regulated by control valves 230′, 232′ and 250′, respectively, suchthat flow through each line can be shut off or allowed irrespective ofthe other lines.

In an embodiment designed to bolster production of heavier oligomerateand maintain liquid phase conditions in the oligomerization reactor zone140, an oligomerate return stream in oligomerate return line 231 may betaken from the recycle oligomerate product stream comprising C₆+ olefinsin the recycle oligomerate product line 230 and be recycled to theoligomerization reactor zone 140 comprising oligomerization catalyst. Inthis case, a control valve 231′ on oligomerate return line 231 is open,so that recycle oligomerate product is recycled to the oligomerizationreactor zone 140 in the oligomerization zone 130. The oligomerizationcatalyst is resistant to excess oligomerization of heavier olefins, sorecycling heavier olefins to the oligomerization catalyst will notresult in excess oligomerization to heavier olefins than diesel. Therecycle oligomerate product stream comprising C₆+ olefins serves tomaintain liquid phase in the oligomerization reactor zone 140 andprovides olefins that can oligomerize to heavier diesel range olefins.In this embodiment, the oligomerization zone 130 is in downstreamcommunication with the first bottom line 214 of the debutanizer column210 and the bottom product line 224 of the depentanizer column 220. In afurther aspect, the recycle oligomerate product line 230 and theoligomerate return line 231 are in downstream communication with theoligomerization zone 130. Consequently, the oligomerization zone 130 isin upstream and downstream communication with the first bottom line 214,the bottom product line 224, the recycle oligomerate product line 230and the oligomerate return line 231.

The concentration of dimethyl sulfide in the oligomerate return streamin the oligomerate return line 231 should be no more than 5 wppm sulfuras dimethylsulfide. Consequently, if the recycle oligomerate productstream in recycle oligomerate product line 230 is taken from theoligomerate bottom product stream comprising C₆+ olefins in the bottomproduct line 224 to be recycled to the oligomerization reactor zone 140,it should comprise no more than 5 wppm sulfur as dimethyl sulfide.Accordingly, the oligomerization recovery zone 200 should be operated toproduce an oligomerate bottom product stream that has no more than 5wppm sulfur as dimethyl sulfide and/or less than 1 wt % C₅ hydrocarbons.

If a refiner desires to make additional propylene in the FCC unit, anembodiment may be used in which an FCC recycle oligomerate stream takenfrom the recycle oligomerate product stream in the recycle oligomerateproduct line 230 from the oligomerate bottom product stream comprisingC₆+ olefins in the bottom product line 224 may be recycled to the FCCrecycle line 280. An FCC recycle oligomerate line 233 may take an FCCrecycle oligomerate stream from the recycle oligomerate stream inrecycle oligomerate line 230 and forward it to the FCC zone 20 throughFCC recycle line 280. The FCC recycle oligomerate line 233 communicatesthe recycle oligomerate line with FCC recycle line 280 and the FCCreaction zone 20. A control valve 233′ on the FCC recycle oligomerateline 233 may be open if recycle oligomerate product to the FCC zone 20is desired. The FCC recycle line 280 will carry the FCC recycleoligomerate stream as feed to the FCC zone 20. In an aspect, the recycleoligomerate product stream in the recycle oligomerate product line 230is in downstream communication with the FCC recovery zone 200. In afurther aspect, the FCC recycle oligomerate line 233 is in downstreamcommunication with the oligomerization zone 130. Hence, in an aspect,the FCC reaction zone 20 is in upstream and downstream communicationwith oligomerization zone 130 and/or FCC recovery zone 100. In a stillfurther aspect, FCC recycle oligomerate line 233 and recycle oligomerateproduct line 230 are in upstream communication with the FCC reactionzone 20 to recycle oligomerate for fluid catalytic cracking down topropylene or other light olefins. One or both of valves 231′ and 233′may be opened or closed depending on the refiner's desire for recycle tothe oligomerization zone 130 or the FCC zone 20, respectively.

In an embodiment in which the oligomerization catalyst is SPA in theoligomerization reactor zone 140 for oligomerizing C₄ olefins or a mixedC₄ and C₅ olefin stream, we have found that a gasoline product streamcan be provided by the oligomerate bottom product stream in bottomproduct line 224. The SPA catalyst minimizes the formation of C₁₂+species with either a C₄ olefin or C₄ and C₅ olefin feed. Consequently,even when heavier olefins than C₄ olefins are present in theoligomerization feed stream, the SPA catalyst manages to keep C₁₂+olefins present in the liquid oligomerate bottom product stream in thebottom product line 224 below less than about 20 wt % even when over 85wt % of feed olefins are converted and particularly when over 90 wt % ofC₄ olefins are converted to oligomerate.

Accordingly, the liquid oligomerate bottom product stream in bottomproduct line 224 provides gasoline range material that meets the EnglerT90 gasoline specification of 193° C. (380° F.) using the ASTM D-86 TestMethod without further treatment when SPA is the second oligomerizationcatalyst in the oligomerization reactor zone 140. That is, 90 wt % ofthe resulting liquid oligomerate bottom product stream, for example, inbottom product line 224 will boil before its temperature is raised to193° C. (380° F.). Consequently, a gasoline oligomerate product streamcan be collected from the liquid oligomerate bottom product stream in agasoline oligomerate product line 250 and blended in the gasoline poolwithout further treatment such as separation or chemical upgrading. Thegasoline oligomerate product line 250 may be in upstream communicationwith a gasoline tank 252 or a gasoline blending line of a gasoline pool.However, further treatment such as partial or full hydrogenation toreduce olefinicity may be contemplated. In such a case, control valves232′ and 230′ may be all or partially closed and control valve 250′ onoligomerate liquid product line 250 may be opened to allow C₆+ gasolineproduct to be sent to the gasoline tank 252 or the gasoline blendingline.

The oligomerization recovery zone 200 may also include a distillateseparator column 240 to which the distillate separator oligomerate feedstream comprising oligomerate C₆+ hydrocarbons may be fed in distillatefeed line 232 taken from the liquid oligomerate bottom product stream inline 224 for further separation. The distillate separator column 240 isin downstream communication with the first bottom line 214 of thedebutanizer column 210 and the bottom product line 224 of thedepentanizer column 220.

The distillate separator column 240 separates the distillate separatoroligomerate feed stream into an gasoline overhead stream in an overheadline 242 comprising C₆, C₇, C₈, C₉, C₁₀ and/or C₁₁ olefins and a bottomdistillate stream comprising C₈+, C₉+, C₁₀+, C₁₁+, or C₁₂+ olefins in adiesel bottom line 244. When maximum production of distillate isdesired, either to obtain diesel product or to recrack the diesel in theFCC zone 20 to make more propylene, the overhead pressure in thedistillate separator column 240 may be between about 10 and about 60 kPa(gauge) and the bottom temperature may be between about 225° and about275° C. When maximum production of gasoline is desired, the overheadpressure in the distillate separator column 240 may be between about 10and about 60 kPa (gauge) and the bottom temperature may be between about190° and about 250° C. The bottom temperature can be adjusted betweenabout 175° and about 275° C. to adjust the bottom product between a C₉+olefin cut and a C₁₂+ olefin cut based on the heaviness of the dieselcut desired by the refiner. The gasoline overhead stream in gasolineoverhead line 242 may have the same composition as described for the C₈olefins of the oligomerate in oligomerate line 156. The diesel bottomsstream in diesel bottoms line 244 may have greater than 30 wt % C₉+isoolefins.

For refiners who are interested in distillate production at a particulartime, the gasoline overhead stream comprising C₈ olefins in the gasolineoverhead line 242 of the distillate separator column can be recycled tothe oligomerization zone 130 to increase the production of distillate.For example, a gasoline overhead recycle stream in gasoline overheadrecycle line 246 may be taken from the gasoline overhead stream ingasoline overhead line 242 and mixed with the fresh oligomerization feedstream in oligomerization feed line 128. A control valve 246′ may beused to completely shut off flow through gasoline overhead recycle line246 or allow partial or full flow therethrough. The gasoline overheadrecycle line 246 may be in downstream communication with theoligomerization recovery zone 200 to generate diesel range material.

Preferably, the gasoline recycle gasoline stream in line 246, which maybe taken from the gasoline overhead in line 242, may be recycled to theoligomerization reactors, 138 and 150 of the oligomerization reactorzone 140 with oligomerization catalyst. The gasoline overhead stream maycomprise C₆-C₁₁ olefins and preferably C₇-C₉ olefins and most preferablyC₈ olefins that can oligomerize with C₄-C₅ olefins in theoligomerization feed stream in the oligomerization zone 130 to dieselrange material comprising C₁₀-C₁₆ diesel product. C₄ olefins continue tooligomerize with C₄ olefins and C₅ olefins if present in the feed.

The oligomerization catalyst, and particularly, the uni-dimensional,10-ring pore structured zeolite, converts a significant fraction of thegasoline-range olefins, such as C₈ olefins, to distillate material byoligomerizing them with feed olefins, such as C₄ and/or C₅ olefins.Additionally, the presence of the gasoline-range olefins also encouragesoligomerization of the feed olefins with each other over the zeolitecatalyst. Surprisingly, the isobutene conversion is lower than normalbutene conversion at high overall butene conversion such as over 90% C₄olefin conversion. When gasoline is recycled from the gasoline overheadline 242 to the oligomerization reactor zone 140 for oligomerizationover uni-dimensional, 10-ring pore structured zeolite, oligomerate fromthe oligomerization zone in oligomerate line 156 may comprise greaterthan 30 wt % C₉+ olefins. Under these circumstances, oligomerate fromthe oligomerization reactor zone in oligomerate line 156 may comprisegreater than 50 wt % or even greater than 60 wt % C₉+ olefins.

In an aspect, the gasoline overhead stream in gasoline overhead line 242may be recovered as product in product gasoline line 248 in downstreamcommunication with the recovery zone 200. A control valve 248′ may beused to completely shut off flow through gasoline product line 248 orallow partial or full flow therethrough. The gasoline product stream maybe subjected to further processing to recover useful components orblended in the gasoline pool. The gasoline product line 248 may be inupstream communication with a gasoline tank 252 or a gasoline blendingline of a gasoline pool. In this aspect, the overhead line 242 of thedistillate separator column may be in upstream communication with thegasoline tank 252 or the gasoline blending line.

In an embodiment, the diesel bottom stream in a diesel bottom line 244may be recycled to the FCC zone 20 in FCC recycle line 280 via a recyclediesel line 260 in downstream communication with the oligomerizationrecovery zone 200 to be cracked to propylene product in the FCC zone. Arecycle diesel bottom stream in recycle diesel line 260 taken from thediesel bottom stream in line 244 may be forwarded to the FCC recycleline 280. The diesel bottom stream may comprise C₉+, C₁₀+, C₁₁+ or C₁₂+olefins that can crack to propylene. A control valve 260′ may be used tocompletely shut off flow through recycle diesel line 260 or allowpartial or full flow therethrough. In this embodiment, the FCC zone 20is in downstream communication with the distillate separator column 240and particularly the diesel bottom line 244.

If the FCC zone 20 comprises a single reactor riser 26, the firstreactor riser 26 may be in downstream communication with the hydrocarbonfeed line 24 and the diesel bottom line 244 of the distillate separatorcolumn 240. If the FCC zone 20 comprises the first reactor riser 26 anda second reactor riser 74, the first reactor riser 26 may be indownstream communication with the hydrocarbon feed line 24 and thesecond reactor riser 74 may be in downstream communication with thebottom line 244 of the distillate separator column 240.

We have found that C₆+ oligomerate and distillate oligomerate subjectedto FCC is converted best over a blend of medium or smaller pore zeoliteblended with a large pore zeolite such as Y zeolite as explainedpreviously with respect to the FCC zone 20. Additionally, oligomerateproduced over the oligomerization catalyst in the oligomerizationreactor zone 140 provides an excellent feed to the FCC zone that can becracked to yield greater quantities of propylene.

In an aspect, the diesel bottom stream may be recovered as product in adiesel product line 262 in downstream communication with theoligomerization recovery zone 200. The diesel product line in line 262is taken from the diesel bottom stream in diesel bottom line 244. Acontrol valve 262′ may be used to completely shut off flow through thediesel product line 262 or allow partial or full flow therethrough. Thediesel product stream may be subjected to further processing to recoveruseful components or blended in the diesel pool. The diesel product line262 may be in upstream communication with a diesel tank 264 or a dieselblending line of a diesel pool. Additionally, LCO from LCO line 107 mayalso be blended with diesel in diesel product line 262.

FIG. 2 depicts an alternative embodiment of the oligomerization recoveryzone 200. Elements in FIG. 2 with the same configuration as in FIG. 1will have the same reference numeral as in FIG. 1. Elements in FIG. 2which have a different configuration as the corresponding element inFIG. 1 will have the same reference numeral but designated with a suffix“a”. The configuration and operation of the embodiment of FIG. 2 isessentially the same as in FIG. 1 with the exceptions noted below.

In FIG. 2, the oligomerization recovery zone 200 a comprises afractionation debutanizer column 210 a in downstream communication withthe oligomerization zone 130. The oligomerate steam in oligomerate line156 is fed to an inlet 181 to the fractionation debutanizer column 210 awhich separates the oligomerate stream between vapor and liquid into afirst vaporous oligomerate overhead light stream in a first overheadline 212 comprising C₄ hydrocarbons, an intermediate side stream inintermediate line 214 a comprising C₅ hydrocarbons and a liquidoligomerate bottom product stream comprising C₆+ olefins in a bottomproduct line 224 a. The intermediate side stream may be taken from aside outlet 215 of the fractionation debutanizer column 210 a. Theintermediate stream may be a liquid collected on a tray in thefractionation debutanizer column 210 a.

The fractionation debutanizer column 210 a feeds the intermediate sidestream from the side outlet 215 of the fractionation debutanizer column210 a to a side stripper column 220 a to separate the intermediate sidestream into a second overhead stream in second overhead line 221comprising C₄− hydrocarbons and a second bottom stream in a secondbottom line 228 a comprising C₅ hydrocarbons. The side stripper column220 a may be in downstream communication with the side outlet 215 of thefractionation debutanizer column 210 a. The second overhead stream 221is fed to the fractionation debutanizer column 210 a at a side inlet223. Consequently, the fractionation debutanizer column 210 a is indownstream communication with the overhead line 221 from the sidestripper column 220 a. Hence, in an aspect, the fractionationdebutanizer column 210 a is in upstream and downstream communicationwith the side stripper column 220 a.

The feed inlet 181 to the fractionation debutanizer column may be at alower elevation than a side inlet 223 from the overhead line 221 fromthe side stripper 220 a. Additionally, the side inlet 223 from theoverhead line 221 from the side stripper 220 a may be at a higherelevation than the side outlet 215. Lastly, the side outlet 215 may beat a higher elevation on the debutanizer column 210 a than the feedinlet 181.

When maximum production of distillate is desired, either to obtaindiesel product or to recrack the diesel in the FCC zone 20 to make morepropylene, the overhead pressure in the debutanizer column 210 a may bebetween about 350 and about 400 kPa (gauge) and the bottom temperaturemay be between about 270° and about 320° C. When maximum production ofgasoline is desired, the overhead pressure in the debutanizer column 210a may be between about 350 and about 400 kPa (gauge) and the bottomtemperature may be between about 170° and about 220° C. The sidestripper column 220 a may have an overhead pressure of between about 400and about 450 kPa and a bottom temperature of between about 60° andabout 115° C. in both modes.

One or both of the first vaporous oligomerate overhead light stream infirst overhead line 212 comprising C₄ hydrocarbons and the second bottomstream in second bottom line 228 a comprising C₅ hydrocarbons may bepurged from the process.

A stream comprising C₅ hydrocarbons may be used to maintain theoligomerization zone 130 in liquid phase and provide additional C₅olefins for oligomerization. An intermediate stream comprising C₅hydrocarbons in intermediate line 222 a may be taken from theintermediate side stream in line 214 a before it is further fractionatedsuch as in the side stripper 220 a and recycled to the oligomerizationzone 130 through an open control valve 222 a′ thereon. Taking a streamof C₅ hydrocarbons from the intermediate side stream removes a largeamount of material from the side stripper column 220 a without requiringit to be further reboiled or condensed thus decreasing its capacity andthe expense to operate. Accordingly, the oligomerization zone 130 is indownstream communication with said side outlet 215.

A recycle oligomerate stream comprising C₆+ olefins may be used tomaintain the oligomerization zone 130 in liquid phase and provideadditional olefins for oligomerization. A recycle oligomerate productstream may be taken in recycle oligomerate product line 230 a throughopen control valve 230 a′ from the liquid oligomerate bottom productstream in the bottom product line 224 a which comprises C₆+ olefins. Anoligomerate return stream in oligomerate return line 231 through opencontrol valve 231′ may be taken from the recycle oligomerate productstream in recycle oligomerate product line 230 a and be recycled to theoligomerization zone 130. The oligomerization zone 130 may be,therefore, in downstream communication with the bottom product line 224a of the fractionation column. The oligomerate return stream inoligomerate return line 231 may be recycled to the oligomerizationreactor zone 140 having the oligomerization catalyst.

Distillate oligomer product may be recycled to the FCC unit to make morepropylene. An FCC recycle oligomerate stream in FCC recycle oligomerateline 233 may be taken from the recycle oligomerate product stream inrecycle oligomerate product line 230 a and be forwarded through openvalve 233′ to the FCC zone 20 in FCC recycle line 280. Accordingly, theFCC zone may be in downstream communication with the bottom product line224 a of the fractionation debutanizer column. Hence, in an aspect, theFCC zone 20 may be in upstream and downstream communication with theoligomerization zone 130 and/or the debutanizer column 210 a.

If the oligomerate bottom product stream has a suitable composition, itmay be taken as gasoline product in line 250 a through control valve 250a′ to a gasoline pool which may comprise a gasoline tank 252 or agasoline blending line. Accordingly, the gasoline tank 252 or thegasoline blending line may be in downstream communication with anoligomerate bottom product line 224 a of said fractionation debutanizercolumn 210 a.

If sufficient diesel is provided in bottom product line 224 a, thegasoline should be separated from the diesel. A distillate separatorfeed stream may be taken from the oligomerate bottom product stream inbottom product line 224 a in line 232 a through open control valve 232a′ to a distillate separator column 240. The distillate separator column240 can separate the distillate separator feed stream into a gasolinestream 242 and a distillate stream 244 as previously described withrespect to FIG. 1. Accordingly, the distillate separator column 240 isin downstream communication with a bottom product line of saidfractionation debutanizer column 210 a.

In the embodiment of FIG. 2, when maximum production of distillate isdesired, either to obtain diesel product or to recrack the diesel in theFCC zone 20 to make more propylene, the overhead pressure in thedistillate separator column 240 may be between about 150 and about 200kPa (gauge) and the bottom temperature may be between about 250° andabout 300° C. When maximum production of gasoline is desired, theoverhead pressure in the debutanizer column 210 may be between about 150and about 200 kPa (gauge) and the bottom temperature may be betweenabout 210° and about 260° C.

The invention will now be further illustrated by the followingnon-limiting examples.

EXAMPLES Example 1

Feed 1 in Table 2 was contacted with four catalysts to determine theireffectiveness in oligomerizing butenes.

TABLE 2 Component Fraction, wt % propylene 0.1 Iso-C₄'s 70.04isobutylene 7.7 1-butene 5.7 2-butene (cis and trans) 16.283-methyl-1-butene 0.16 acetone 0.02 Total 100

Catalyst A is an MTT catalyst purchased from Zeolyst having a productcode Z2K019E and extruded with alumina to be 25 wt % zeolite. Of MTTzeolite powder, 53.7 grams was combined with 2.0 grams Methocel and208.3 grams Catapal B boehmite. These powders were mixed in a mullerbefore a mixture of 18.2 g HNO₃ and 133 grams distilled water was addedto the powders. The composition was blended thoroughly in the muller toeffect an extrudable dough of about 52% LOI. The dough then was extrudedthrough a die plate to form cylindrical extrudates having a diameter ofabout 3.18 mm. The extrudates then were air dried, and calcined at atemperature of about 550° C. The MTT catalyst was not selectivated toneutralize surface acid sites such as with an amine.

Catalyst B is a SPA catalyst commercially available from UOP LLC.

Catalyst C is an MTW catalyst with a silica-to-alumina ratio of 36:1. OfMTW zeolite powder made in accordance with the teaching of U.S. Pat. No.7,525,008 B2, 26.4 grams was combined with and 135.1 grams Versal 251boehmite. These powders were mixed in a muller before a mixture of 15.2grams of nitric acid and 65 grams of distilled water were added to thepowders. The composition was blended thoroughly in the muller to effectan extrudable dough of about 48% LOI. The dough then was extrudedthrough a die plate to form cylindrical extrudates having a diameter ofabout 1/32″. The extrudates then were air dried and calcined at atemperature of about 550° C.

Catalyst D is an MFI catalyst purchased from Zeolyst having a productcode of CBV-8014 having a silica-to-alumina ratio of 80:1 and extrudedwith alumina at 25 wt % zeolite. Of MFI-80 zeolite powder, 53.8 gramswas combined with 205.5 grams Catapal B boehmite and 2 grams ofMethocel. These powders were mixed in a muller before a mixture of 12.1grams nitric acid and 115.7 grams distilled water were added to thepowders. The composition was blended thoroughly in the muller, then anadditional 40 grams of water was added to effect an extrudable dough ofabout 53% LOI. The dough then was extruded through a die plate to formcylindrical extrudates having a diameter of about 3.18 mm. Theextrudates then were air dried, and calcined at a temperature of about550° C.

The experiments were operated at 6.2 MPa and inlet temperatures atintervals between 160° and 240° C. to obtain different normal buteneconversions. Results are shown in FIGS. 3 and 4. In FIG. 3, C₈ to C₁₁olefin selectivity is plotted against normal butene conversion toprovide profiles for each catalyst.

Table 3 compares the RONC ±3 for each product by catalyst and provides akey to FIG. 3. The SPA catalyst B is superior, but the MTT catalyst A isthe least effective in producing gasoline range olefins.

TABLE 3 Catalyst RONC A MTT circles 92 B SPA diamonds 96 C MTW triangles97 D MFI-80 asterisks 95

The SPA catalyst was able to achieve over 95 wt % yield of gasolinehaving a RONC of >95 and with an Engler T90 value of 185° C. for theentire product. The T-90 gasoline specification is less than 193° C.

In FIG. 4, C₁₂+ olefin selectivity is plotted against normal buteneconversion to provide profiles for each catalyst. Table 4 compares thederived cetane number ±2 for each product by catalyst and provides a keyto FIG. 4.

TABLE 4 Catalyst Cetane A MTT circles 41 B SPA diamonds <14 C MTWtriangles 28 D MFI-80 asterisks 36

FIG. 4 shows that the MTT catalyst provides the highest C₁₂+ olefinselectivity which reaches over 70 wt %. These selectivities are from asingle pass of the feed stream through the oligomerization reactor.Additionally, the MTT catalyst provided C₁₂+ oligomerate with thehighest derived cetane. Cetane was derived using ASTM D6890 on the C₁₂+fraction at the 204° C. (400° F.) cut point. Conversely to gasolineselectivity, the MTT catalyst A is superior, but the SPA catalyst B isthe least effective in producing diesel range olefins.

The MTT catalyst was able to produce diesel with a cetane rating ofgreater than 40. The diesel cloud point was determined by ASTM D2500 tobe −66° C. and the T90 was 319° C. using ASTM D86 Method. The T90specification for diesel in the United States is between 282 and 338°C., so the diesel product meets the U.S. diesel standard.

Example 2

A comprehensive two-dimensional gas chromatography with flame ionizationdetection (GCxGC-FID) method was developed and utilized to analyze thecomposition of light olefin oligomerization product streams. To developthe peak identifications, a GCxGC instrument equipped with a time offlight mass spectrometer (TOFMS) was used. Peak identifications werechecked against a table of C₈ olefin boiling points for consistency andby performing GC-FID of the olefinic sample with and withouthydrogenation catalyst in the GC inlet to ensure that peaks assigned toa particular C₈ mono-olefin moved to their respective saturated C₈isoparaffins. The identification of C₈ paraffin isomers can be achievedusing the UOP690 method. Careful matching of chromatographic conditionsbetween GCxGC-FID and GCxGC-TOFMS allows one to translateidentifications made from the TOFMS analysis to the GCxGC-FID forquantitative analysis. The following 48 compounds in the C₈ region wereidentified and quantified:

C₈ olefin species identified are listed as follows:2,3-dimethyl-2-butene, 3,4-dimethyl-2-pentene, 3,4-dimethyl-2-pentene,2,4,4-trimethyl-1-pentene, 2,2-dimethyl-trans-3-hexene,2,5-dimethyl-3-hexene, 3,3-dimethyl-1-hexene, 3,4,4-trimethyl-1-pentene,2,4,4-trimethyl-2-pentene, 4,4-dimethyl-2-hexene, 4,4-dimethyl-1-hexene,2,3,4-trimethyl-1-pentene, 2,3,3-trimethyl-1-pentene,2,4-dimethyl-trans-3-hexene, 2,4-dimethyl-cis-3-hexene,3,3-dimethyl-2-ethyl-1-butene, 2,4-dimethyl-1-hexene,2,3-dimethyl-1-hexene, 2-methyl-3-heptene, 3,4,4-trimethyl-2-pentene,2,5-dimethyl-2-hexene, 5-methyl-3-heptene, 3,5-dimethyl-2-hexene,6-methyl-3-heptene, 4-methyl-1-heptene,4-methyl-3-ethyl-trans-2-pentene, 2,3-dimethyl-3-hexene,4-methyl-3-ethyl-cis-2-pentene, 3,4-dimethyl-2-hexene, 3-ethyl-3-hexene,6-methyl-2-heptene, 2,3,4-trimethyl-2-pentene,2-methyl-3-ethyl-2-pentene, 5-methyl-2-heptene, 2-n-propyl-1-pentene,4-methyl-3-heptene, 2-ethyl-1-hexene, 2-methyl-1-heptene,3-methyl-3-heptene, trans-3-octene, 2,3-dimethyl-2-hexene,3-methyl-2-heptene, 3,4-dimethyl-trans-3-hexene, cis-3-octene,2-methyl-2-heptene, trans-2-octene, cis-2-octene, and3,4-dimethyl-cis-3-hexene.

C₈ olefins in the oligomerate produced by all four catalysts wereevaluated by the GCxGC-FID method to characterize oligomerate productcomposite by olefin type. GCxGC analysis on the composite product of theexperiment was used to compare the product olefinic isomers fromCatalysts A and B as shown in Table 5.

TABLE 5 Fraction from Fraction from Isomer Species Catalyst A, wt %Catalyst B, wt % C₅ olefins 0.02 3.12 C₆ olefins 1.50 0.25 C₇ olefins1.13 0.92 linear C₈═ 0.91 0.03 methyl-heptenes 10.03 1.68dimethyl-hexenes 13.25 18.70 trimethyl-pentenes 7.24 52.63 C₉ olefins3.03 3.63 C₁₀ olefins 1.92 1.40 C₁₁ olefins 5.67 7.13 C₁₂ olefins 29.866.64 C₁₃ olefins 3.13 0.56 C₁₄ olefins 1.61 0.17 C₁₅ olefins 3.28 0.37C₁₆ olefins 13.37 0.25 C₁₇ olefins 1.47 0.00 C₁₈ olefins 0.64 0.00 C₁₉olefins 1.12 0.00 Other Olefins and 0.82 2.52 Polar Unknowns Total100.00 100.00

Catalyst B, SPA, produces over 70 wt % C₈ olefins with over 70 wt % ofthe C₈ olefins being trimethyl pentenes. However, Catalyst A, MTT,produces only just over 31 wt % C₈ olefins of which only 23 wt % of theC₈ olefins are trimethyl pentenes. Catalyst A produced almost 30 wt %C₁₂ olefins. It is evident that MTT can produce a more linear and largerproduct from light olefins such as butene.

Comparisons are shown in Table 6. All percentages are in weight percent.“Composition Fraction” is the fraction of the species in the entirecomposition. “Olefin Fraction” is the fraction of the species among theC₈ olefins. “Average Branches” for the C₈ olefins is the averagebranches or alkyl groups per olefin molecule calculated by the ratio ofthe sum of the total weight of each isomer of branched C₈ olefinsmultiplied by the number of alkyl groups of that isomer in thecomposition divided by the total weight of normal octene, methylheptene, dimethyl hexene and trimethyl pentene in the composition.“Olefin Isomer Fraction” is fraction of C₈ olefin isomer with thestructure among all C₈ olefins. “TMP/C₈ Olefins” is the ratio oftrimethyl pentene among linear octene, methyl heptene, dimethyl hexeneand trimethyl pentene.

TABLE 6 Catalysts C₈ Olefin Species A B C D Composition Fraction Type Icomposition, % 0.6 2.1 0.5 2.3 Type II composition, % 3.3 1.0 0.4 3.5Type III composition, % 6.8 16.2 3.1 15.4 Type IV composition, % 14.014.6 3.7 21.4 Type V composition, % 4.8 19.5 3.8 13.9 Total 29.5 53.311.5 56.3 Olefin Fraction Type I olefin, % 2.1 4.0 4.4 4.0 Type IIolefin, % 11.3 1.8 3.4 6.1 Type III olefin, % 22.8 30.3 27.1 27.3 TypeIV olefin, % 47.3 27.3 31.7 38.0 Type V olefin, % 16.3 36.6 33.4 24.7Total 100 100 100 100 Average Branches 1.98 2.75 2.55 2.32 C₈ OlefinIsomer Fraction Linear octene, % 2.8 0.0 0.1 0.7 Methyl heptene, % 27.32.1 5.1 11.9 Dimethyl hexene, % 34.9 20.0 32.9 38.7 Trimethyl pentene, %31.3 75.4 59.2 44.4 Other C₈ monoolefins, % 3.8 2.5 2.8 4.4 TMP/C₈Olefins, % 32.5 77.3 60.9 46.4

The fraction of Type 2 disubstituted C₈ olefins in the total C₈ olefinsfor Catalyst A was 11.3 wt % which was much higher than all the othercatalysts. The ratio of Type 2 disubstituted C₈ olefins to Type 1monosubstituted C₈ olefins for catalyst A was 5.3. All the othercatalysts had the same ratio of less than one. The fraction of Type 4trisubstituted C₈ olefins in the total C₈ olefins in the oligomerate forCatalyst A was 47 wt %. All of the other catalysts had the same fractionof no more than about 38 wt %. The average branch per hydrocarbonmolecule for Catalyst A was 1.98; whereas, the other catalysts were allover 2. The ratio of trimethyl pentene to the total C₈ olefins in theoligomerate was 32.5; whereas all of the other catalysts had ratios over46.

Example 3

Two types of feed were oligomerized over oligomerization catalyst A ofExample 1, MTT zeolite. Feeds 1 and 2 contacted with catalyst A areshown in Table 7. Feed 1 is from Example 1.

TABLE 7 Feed 1 Feed 2 Component Fraction, wt % Fraction, wt % propylene0.1 0.1 isobutane 70.04 9.73 isobutylene 7.7 6.3 1-butene 5.7 4.92-methyl-2-butene 0 9.0 2-butene (cis & trans) 16.28 9.8 3-met-1-butene0.16 0.16 n-hexane 0 60 acetone 0.02 0.01 Total 100 100

In Feed 2, C₅ olefin is made up of 2-methyl-2-butene and3-methyl-1-butene which comprises 9.16 wt % of the reaction mixturerepresenting about a third of the olefins in the feed. 3-methyl-1-buteneis present in both feeds in small amounts. Propylene was present at lessthan 0.1 wt % in both feeds.

The reaction conditions were 6.2 MPa and a 1.5 WHSV. The maximumcatalyst bed temperature was 220° C. Oligomerization achievements areshown in Table 8.

TABLE 8 Feed 1 Feed 2 Inlet Temperature, ° C. 192 198 C₄ olefinconversion, % 98 99 nC₄ olefin conversion, % 97 99 C₅ olefin conversion,% n/a 95 C₅-C₇ selectivity, wt % 3 5 C₈-C₁₁ selectivity, wt % 26 40C₁₂-C₁₅ selectivity, wt % 48 40 C₁₆+ selectivity, wt % 23 16 Total C₉+selectivity, wt % 78 79 Total C₁₂+ selectivity, wt % 71 56 Net gasolineyield, wt % 35 44 Net distillate yield, wt % 76 77

Normal C₄ olefin conversion reached 99% with C₅ olefins in Feed 2 andwas 97 wt % without C₅ olefins in Feed 1. C₅ olefin conversion reached95%. With C₅ olefins in Feed 2, it was expected that a greaterproportion of heavier, distillate range olefins would be made. However,the Feed 2 with C₅ olefins oligomerized to a greater selectivity oflighter, gasoline range product in the C₅-C₇ and C₈-C₁₁ range and asmaller selectivity to heavier distillate range product in the C₁₂-C₁₅and C₁₆+ range.

This surprising result indicates that by adding C₅ olefins to the feed,a greater yield of gasoline can be made over Catalyst A, MTT. This isconfirmed by the greater net yield of gasoline and the lower selectivityto C₁₂+ fraction for Feed 2 than for Feed 1. Also, but not to the samedegree, by adding C₅ olefins to the feed, a greater yield of distillaterange material can be made. This is confirmed by the greater net yieldof distillate for Feed 2 than for Feed 1 on a single pass basis.Gasoline yield was classified by product meeting the Engler T90requirement and distillate yield was classified by product boiling over150° C. (300° F.).

Example 4

Three types of feed were oligomerized over oligomerization catalyst B ofExample 1, SPA. The feeds contacted with catalyst B are shown in Table9. Feed 2 is the same as Feed 2 in Example 3. Isooctane was used as adiluent with Feed 3 because it is expected to behave inertly just asisobutane. Feed 4 is similar to Feed 2 but has the pentenes evenly splitbetween iso and normal pentenes, which is roughly expected to be foundin an FCC product, and diluted with isobutane instead of hexane andisobutane.

TABLE 9 Feed 2 Feed 3 Feed 4 Component Fraction, wt % Fraction, wt %Fraction, wt % propylene 0.1 0.08 0.1 1,3-butadiene 0 0.28 0 isobutane9.73 6.45 69.72 isobutylene 6.3 7.30 6.3 1-butene 4.9 5.07 4.92-methyl-2-butene 9.0 0 4.5 2-butene (cis & trans) 9.8 11.33 9.83-met-1-butene 0.16 0.16 0.16 2-pentene 0 0 4.5 cyclopentane 0 0.28 0n-hexane 60 0 0 isooctane 0 60.01 0 acetone 0.01 0.01 0.02 Total 100 100100

The reaction pressure was 3.5 MPa. Oligomerization achievements areshown in Table 10.

TABLE 10 Feed 2 Feed 3 Feed 4 WHSV, hr⁻¹ .75 1.5 .75 Pressure, MPa 3.53.5 6.2 Inlet Temperature, ° C. 190 170 178 Maximum Temperature, ° C.198 192 198 C₄ olefin conversion, % 95 92 93 nC₄ olefin conversion, % 9590 93 C₅ olefin conversion, % 90 n/a 86 C₅-C₇ selectivity, wt % 8 5 8C₈-C₁₁ selectivity, wt % 77 79 77 C₁₂-C₁₅ selectivity, wt % 15 16 15C₁₆+ selectivity, wt % 0.3 0.1 .01 Total C₉+ selectivity, wt % 35 20 25Total C₁₂+ selectivity, wt % 17 16 15 Net gasoline yield, wt % 94 92 91Net distillate yield, wt % 32 18 23 RONC (±3) 97 96 96 Engler T-90, ° C.182 164 182

Olefin conversion was at least 90% and normal butene conversion was over90%. Normal C₄ olefin conversion reached 90% with C₅ olefins in Feed 2and was 97% without C₅ olefins in Feed 1. C₅ olefin conversion reached90% but was less when both iso and normal C₅ olefins were in the feed.

It can be seen that the SPA catalyst minimized the formation of C₁₂+species to below 20 wt % at 16 and 17 wt %, respectively, without andwith C₅ olefins in the oligomerization feed stream. When normal C₅olefins were added, C₁₂+ formation reduced to 15 wt %. The C₆+oligomerate produced by all three feeds met the gasoline T-90 specindicating that 90 wt % boiled at temperatures under 193° C. (380° F.).The Research Octane Number for all three products was high, over 95,with and without substantial C₅ olefins present.

Example 5

Feed 2 with C₅ olefins present was subjected to oligomerization withCatalyst B, SPA, at different conditions to obtain different buteneconversions. C₅ olefin is made up of 2-methyl-2-butene and3-methyl-1-buene which comprises 9.16 wt % of the reaction mixturerepresenting about a third of the olefins in the feed. Propylene waspresent at less than 0.1 wt %. Table 11 shows the legend of componentolefins illustrated in FIG. 5.

TABLE 11 Component Symbols in FIG. 5 isobutylene Circle 1-buteneTriangle 2-methyl-2-butene and Diamond 3-met-1-butene 2-butene (cis &trans) Asterisk

FIG. 5 shows conversions for each of the olefins in Feed 2 over CatalystB, SPA. Over 95% conversion of normal C₄ olefins was achieved at over90% butene conversion. Pentene conversion reached 90% at over 90% buteneconversion. Normal butene conversion actually exceeded isobuteneconversion at high butene conversion over about 95%.

Example 6

Three feeds were oligomerized to demonstrate the ability of Catalyst A,MTT, to produce diesel range oligomerate by recycling gasoline rangeoligomerate to the oligomerization zone. Feed 1 from Example 1 with anisobutane diluent was tested along with Feed 5 which had a normal hexanediluent and Feed 6 which had an isobutane diluent but spiked withdiisobutene to represent recycled gasoline range oligomers. The feedsare shown in Table 12. The symbols in FIG. 6 correspond to thoseindicated in the last row of Table 12.

TABLE 12 Feed 1 Feed 5 Feed 6 Fraction, Fraction, Fraction, Component wt% wt % wt % propylene 0.1 0.08 0.08 isobutane 70.04 15.75 15.75isobutylene 7.7 7.3 7.3 1-butene 5.7 5.1 5.1 2-butene (cis & trans)16.28 11.6 11.6 3-met-1-butene 0.16 0.16 0.16 n-hexane 0 60 0 acetone0.02 0.01 0.01 tert-butyl alcohol 0 0.0008 0.0008 diisobutene 0 0 60Total 100 100 100 FIG. 6 symbol square diamond asterisk

The oligomerization conditions included 6.2 MPa pressure, 0.75 WHSV overCatalyst A, MTT. Normal butene conversion as a function of temperatureis graphed in FIG. 6 for the three feeds.

FIG. 6 demonstrates that Feed 6 with the diisobutene oligomer hasgreater normal butene conversion at equivalent temperatures between 180°and 240° C. Consequently, gasoline oligomerate recycle to theoligomerization zone will improve normal C₄ conversion. Buteneconversion for Feed 5 is shown in FIG. 7 and for Feed 6 is shown in FIG.8. The key for FIGS. 7 and 8 is shown in Table 13.

TABLE 13 Component Symbols in FIGS. 7 & 8 isobutylene Circle 1-buteneTriangle 2-butene (cis & trans) Asterisk

At higher butene conversions and with diisobutene recycle, isobutene hasthe lowest conversion with both 1-butene and 2-butene having greateroligomerization to oligomers. However, without diisobutene recycle,isobutene undergoes the greatest conversion, but with 1-buteneconversion apparently surpassing isobutene conversion at over 94% totalbutene conversion. We expect the same performance for Feed 1 withisobutane diluent.

Table 14 gives feed performance for the three feeds at conditionsselected to achieve high butene conversion and high C₁₂+ yield including6.2 MPa of pressure.

TABLE 14 Run Feed 1 Feed 5 Feed 6 WHSV, hr⁻¹ 0.9 0.6 0.7 Maximum BedTemperature, ° C. 240 236 239 C₄ olefin conversion, % 95 96 95 n-C₄olefin conversion, % 95 95 97 i-C₄ olefin conversion, % 96 97 91 1-C₄olefin conversion, % 97 98 97 2-C₄ olefin conversion, % 94 94 97 C₅-C₇selectivity, wt % 3 3 0.8 C₈-C₁₁ selectivity, wt % 27 27 26 C₁₂-C₁₅selectivity, wt % 49 52 39 C₁₆+ selectivity, wt % 20 19 34 Total C₉+selectivity, wt % 76 77 77 Total C₁₂+ selectivity, wt % 70 71 73 DieselYield, wt % 72 74 73

C₁₂+ selectivity increased and C₁₆+ increased substantially withdiisobutene presence over the feeds without diisobutene presence. Yieldcalculated by multiplying C₄ olefin conversion by total C₉+ selectivitytaken at the 150° C. (300° F.) cut point was over 70% for all feedsbased on a single pass through the oligomerization reactor.

Example 7

Feed 1 and Feed 5 were reacted over Catalyst A, MTT, at 6.2 MPa and 0.75WHSV. A graph of selectivity as a function of maximum catalyst bedtemperature in FIG. 9 shows optimal maximum bed temperature betweenabout 220° and about 240° C. has an apex that corresponds with maximalC₁₂+ olefin selectivity and to a minimum C₈-C₁₁ olefin selectivity and aC₅-C₇ olefin selectivity. Table 15 provides a key for FIG. 9. In FIG. 9,solid points and lines represent Feed 1; whereas; hollow points anddashed lines represent Feed 5.

TABLE 15 Symbol Solid - Feed 1 Hollow - Feed 5 C₁₂+ olefin selectivityTriangles C₈-C₁₁ olefin selectivity Circles C₅-C₇ olefin selectivityGreek Crosses Asterisks

Example 8

Three different feeds representing product oligomerate were subjected tomicro reactor cracking testing over three different catalysts. The threefeeds were 2,4,4-trimethyl-1-pentene, 1-octene and mixed C₁₂ and largerolefins which contained linear molecules. The three catalysts included aZSM-5 additive with 40 wt % ZSM-5 crystals, Zeolite Y and a blend of 25wt % of the ZSM-5 additive and 75 wt % Zeolite Y such that 10 wt % ofthe blend was ZSM-5 crystals. The test conditions included 565° C., 10.3kPa (gauge) and a residence time of 0.05 seconds at standard feedconditions of 25° C. and atmospheric pressure. The feeds were a mixtureof 10 mol-% hydrocarbon, 5 mol-% steam, and the balance nitrogen. Table16 provides the key for FIGS. 10-12.

TABLE 16 Component Key Conversion, % Diagonal lines C₃ olefin yield, wt% Dotted fill C₄ olefin yield, wt % Cross Hatch C₅ olefin yield, wt %Diagonal Cross Hatch ZSM-5 Left Zeolite Y Middle Blend of ZSM-5 andZeolite Y Right Trimethyl pentene feed FIG. 10 1-Octene feed FIG. 11Mixed C₁₂ olefins FIG. 12

FIG. 10 reveals that achieving high conversion of2,4,4,-trimethyl-1-pentene over ZSM-5 alone was very difficult. The samefeed over Zeolite Y or the blend of ZSM-5 and Zeolite Y reached highconversion easily. The blend of ZSM-5 and Y zeolite had the highestpropylene yield. FIG. 11 shows that the conversion of 1-octene was veryhigh over all three catalysts. We saw a similar pattern for methylheptene in a separate test. Again, the blend of ZSM-5 and Y zeolite hadthe highest propylene yield. FIG. 12 shows that conversion of C₁₂ andlarger olefins, propylene tetramer, over the blend of ZSM-5 and Yzeolite had the highest propylene yield of all the feeds tested. ZSM-5alone was not able to achieve much conversion of the C₁₂ and largerolefin feed.

This example establishes that feeding oligomerate produced over CatalystA of Example 1, MTT, which produces less of the trimethyl pentene butmore of the linear and less-branched C₈ olefins and C₁₂ olefins to anFCC unit will provide the best FCC feed to crack into the mostpropylene.

Example 9

Three feeds were reacted over FCC equilibrium catalyst comprising 8 wt %ZSM-5. Feed 7 comprised hydrotreated VGO with a hydrogen content of 13.0wt %. Feed 8 comprised the same VGO mixed with 25 wt % oligomerateproduct catalyzed by Catalyst A of Example 1. Feed 9 comprised the sameVGO mixed with 25 wt % oligomerate product catalyzed by Catalyst B ofExample 1. The feeds were heated to 260-287° C. and contacted with theFCC catalyst in a riser apparatus to achieve 2.5-3.0 seconds ofresidence time. FIG. 13 plots C₃ olefin yield versus VGO conversion. Thekey for FIG. 13 is in Table 17.

TABLE 17 Feed Composition Key Feed 7 VGO Solid diamond Feed 8 VGO/MTToligomerate Square Feed 9 VGO/SPA oligomerate Triangle

FIG. 13 shows that recycle of oligomerate product to the FCC zone canboost propylene production. At the apex of the propylene yield curve ofVGO alone, the feed comprising VGO and oligomerate provided 3.2 wt %more propylene yield from the FCC zone.

Specific Embodiments

While the following is described in conjunction with specificembodiments, it will be understood that this description is intended toillustrate and not limit the scope of the preceding description and theappended claims.

A first embodiment of the invention is a process for making propylenecomprising cracking a hydrocarbon feed stream and a distillate recyclestream comprising distillate hydrocarbons over an FCC catalyst in an FCCzone to produce a cracked product stream; recovering a propylene productstream from the cracked product stream; obtaining an oligomerizationfeed stream comprising C₄ olefins from the cracked product stream;passing the oligomerization feed stream to an oligomerization zone tooligomerize C₄ olefins in the oligomerization feed stream to produce anoligomerate stream; and separating the oligomerate stream from theoligomerization zone in a recovery zone to provide a gasoline stream andthe distillate recycle stream comprising distillate hydrocarbons. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the first embodiment in this paragraph furthercomprising oligomerizing the C₄ olefins over a zeolite catalyst having auni-dimensional 10-ring pore structure. An embodiment of the inventionis one, any or all of prior embodiments in this paragraph up through thefirst embodiment in this paragraph wherein the zeolite catalyst is anMTT. An embodiment of the invention is one, any or all of priorembodiments in this paragraph up through the first embodiment in thisparagraph wherein the maximum temperature of a bed of the zeolitecatalyst is between about 200 and about 250° C. An embodiment of theinvention is one, any or all of prior embodiments in this paragraph upthrough the first embodiment in this paragraph further comprisingoligomerizing the C₄ olefins over a solid phosphoric acid catalyst. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the first embodiment in this paragraph whereinoligomerization feed stream also comprises C₅ olefins and the C₄ olefinsalso oligomerize with the C₅ olefins in the oligomerization zone. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the first embodiment in this paragraph whereinthe distillate recycle stream comprises C₁₂ olefins. An embodiment ofthe invention is one, any or all of prior embodiments in this paragraphup through the first embodiment in this paragraph wherein the distillaterecycle stream and the hydrocarbon feed stream are cracked in the sameriser in the FCC reaction zone. An embodiment of the invention is one,any or all of prior embodiments in this paragraph up through the firstembodiment in this paragraph further comprising obtaining anintermediate stream comprising C₅ hydrocarbons from the recovery zoneand purging a purge stream and recycling a C₅ recycle stream to theoligomerization zone both from the intermediate stream. An embodiment ofthe invention is one, any or all of prior embodiments in this paragraphup through the first embodiment in this paragraph further comprisingsending the gasoline stream to a gasoline tank or a gasoline blendingline.

A second embodiment of the invention is a process for making propylenecomprising cracking a hydrocarbon feed stream and a distillate recyclestream comprising distillate hydrocarbons over an FCC catalyst in an FCCzone to produce spent FCC catalyst and a cracked product stream;regenerating the spent FCC catalyst; recovering a propylene productstream from the cracked product stream; obtaining an oligomerizationfeed stream comprising C₄ olefins from the cracked product stream;passing the oligomerization feed stream to an oligomerization zone tooligomerize C₄ olefins in the oligomerization feed stream over a zeolitecatalyst having a uni-dimensional 10-ring pore structure to produce anoligomerate stream; and separating the oligomerate stream from theoligomerization zone in a recovery zone to provide a gasoline stream andthe distillate recycle stream comprising distillate hydrocarbons. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the second embodiment in this paragraphwherein the zeolite catalyst is an MTT. An embodiment of the inventionis one, any or all of prior embodiments in this paragraph up through thesecond embodiment in this paragraph wherein oligomerization feed streamalso comprises C₅ olefins and the C₄ olefins also oligomerize with theC₅ olefins in the oligomerization zone. An embodiment of the inventionis one, any or all of prior embodiments in this paragraph up through thesecond embodiment in this paragraph wherein the distillate recyclestream comprises C₁₂ olefins. An embodiment of the invention is one, anyor all of prior embodiments in this paragraph up through the secondembodiment in this paragraph wherein the distillate recycle stream andthe hydrocarbon feed stream are cracked in the same riser in the FCCreaction zone. An embodiment of the invention is one, any or all ofprior embodiments in this paragraph up through the second embodiment inthis paragraph further comprising sending the gasoline stream to agasoline tank or a gasoline blending line.

A third embodiment of the invention is a process for making propylenecomprising cracking a hydrocarbon feed stream and a distillate recyclestream comprising distillate hydrocarbons over an FCC catalyst in an FCCzone to produce spent FCC catalyst and a cracked product stream;regenerating the spent FCC catalyst; recovering a propylene productstream from the cracked product stream; obtaining an oligomerizationfeed stream comprising C₄ olefins from the cracked product stream;passing the oligomerization feed stream to an oligomerization zone tooligomerize C₄ olefins in the oligomerization feed stream to produce anoligomerate stream; separating an oligomerate stream from theoligomerization zone in a recovery zone to provide a gasoline stream andthe distillate recycle stream comprising distillate hydrocarbons; andsending the gasoline stream to a gasoline tank or a gasoline blendingline. An embodiment of the invention is one, any or all of priorembodiments in this paragraph up through the third embodiment in thisparagraph further comprising oligomerizing the C₄ olefins over an MTTzeolite. An embodiment of the invention is one, any or all of priorembodiments in this paragraph up through the third embodiment in thisparagraph wherein the distillate recycle stream comprises C₁₂ olefins.An embodiment of the invention is one, any or all of prior embodimentsin this paragraph up through the third embodiment in this paragraphwherein the distillate recycle stream and the hydrocarbon feed streamare cracked in the same riser in the FCC reaction zone.

A fourth embodiment of the invention is an apparatus for makingpropylene comprising an FCC zone for cracking a hydrocarbon feed streamfrom a hydrocarbon feed line and a distillate recycle stream comprisingdistillate hydrocarbons over an FCC catalyst to produce a crackedproduct stream; an FCC recovery zone in communication with the FCC zonefor recovering a propylene product stream and an oligomerization feedstream comprising C₄ olefins from the cracked product stream; anoligomerization zone in communication with the FCC recovery zone foroligomerizing C₄ olefins in the oligomerization feed stream to producean oligomerate stream; and an oligomerization recovery zone incommunication with the oligomerization zone for separating theoligomerate stream; and a distillate separator column in theoligomerization recovery zone for separating a gasoline stream from adistillate stream, the FCC zone being in communication with thedistillate separator column. An embodiment of the invention is one, anyor all of prior embodiments in this paragraph up through the fourthembodiment in this paragraph wherein the FCC zone is in communicationwith a bottom line of the distillate separator column. An embodiment ofthe invention is one, any or all of prior embodiments in this paragraphup through the fourth embodiment in this paragraph wherein the FCC zonecomprises a reactor riser which is in communication with the hydrocarbonfeed line and the bottom line of the distillate separator column. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the fourth embodiment in this paragraphwherein the FCC zone comprises a first reactor riser which is incommunication with the hydrocarbon feed line and a second reactor riserwhich is in communication with the bottom line of the distillateseparator column. An embodiment of the invention is one, any or all ofprior embodiments in this paragraph up through the fourth embodiment inthis paragraph wherein the FCC zone comprises a reactor riser which isin communication with the hydrocarbon feed line and the distillateseparator column. An embodiment of the invention is one, any or all ofprior embodiments in this paragraph up through the fourth embodiment inthis paragraph wherein the FCC zone comprises a first reactor riserwhich is in communication with the hydrocarbon feed line and a secondreactor riser which is in communication with the distillate separatorcolumn. An embodiment of the invention is one, any or all of priorembodiments in this paragraph up through the fourth embodiment in thisparagraph further comprising an overhead line of the distillateseparator column in communication with a gasoline tank or a gasolineblending line. An embodiment of the invention is one, any or all ofprior embodiments in this paragraph up through the fourth embodiment inthis paragraph wherein the oligomerization recovery zone furthercomprises a debutanizer column and the oligomerization zone is incommunication with a bottom line of the debutanizer column. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the fourth embodiment in this paragraphwherein the distillate separation column is in communication with thebottom line of the debutanizer column.

A fifth embodiment of the invention is an apparatus for making propylenecomprising an FCC zone for cracking a hydrocarbon feed stream in ahydrocarbon feed line and a distillate recycle stream comprisingdistillate hydrocarbons over an FCC catalyst to produce spent FCCcatalyst and a cracked product stream; a regeneration vessel in the FCCzone for regenerating the spent FCC catalyst; an FCC product recoveryzone in communication with the FCC zone for recovering a propyleneproduct stream and an oligomerization feed stream comprising C₄ olefinsfrom the cracked product stream; an oligomerization zone incommunication with the FCC product recovery zone for oligomerizing C₄olefins in the oligomerization feed stream to produce an oligomeratestream; and an oligomerization recovery zone in communication with theoligomerization zone for separating the oligomerate stream; and adistillate separator column in the oligomerization recovery zone forseparating a gasoline stream from a distillate stream, the FCC zonebeing in communication with a bottom line of the distillate separatorcolumn. An embodiment of the invention is one, any or all of priorembodiments in this paragraph up through the fifth embodiment in thisparagraph wherein the FCC zone comprises a reactor riser which is incommunication with the hydrocarbon feed line and the bottom line of thedistillate separator column. An embodiment of the invention is one, anyor all of prior embodiments in this paragraph up through the fifthembodiment in this paragraph wherein the FCC zone comprises a firstreactor riser which is in communication with the hydrocarbon feed lineand a second reactor riser which is in communication with the bottomline of the distillate separator column. An embodiment of the inventionis one, any or all of prior embodiments in this paragraph up through thefifth embodiment in this paragraph further comprising an overhead lineof the distillate separator column in communication with a gasoline tankor a gasoline blending line. An embodiment of the invention is one, anyor all of prior embodiments in this paragraph up through the fifthembodiment in this paragraph wherein the oligomerization recovery zonefurther comprises a debutanizer column and the oligomerization zone isin communication with a bottom line of the debutanizer column and thedistillate separator column is in communication with a bottom line ofthe debutanizer column. An embodiment of the invention is one, any orall of prior embodiments in this paragraph up through the fifthembodiment in this paragraph wherein the distillate separation column isin communication with a bottom line of the debutanizer column.

A sixth embodiment of the invention is an apparatus for making propylenecomprising an FCC zone for cracking a hydrocarbon feed stream in ahydrocarbon feed line and a distillate recycle stream comprisingdistillate hydrocarbons over an FCC catalyst to produce spent FCCcatalyst and a cracked product stream; a regeneration vessel in the FCCzone for regenerating the spent FCC catalyst; an FCC recovery zone incommunication with the FCC zone for recovering a propylene productstream and an oligomerization feed stream comprising C₄ olefins from thecracked product stream; an oligomerization zone in communication withthe FCC recovery zone for oligomerizing C₄ olefins in theoligomerization feed stream to produce an oligomerate stream; and anoligomerization recovery zone in communication with the oligomerizationzone for separating the oligomerate stream; and a distillate separatorcolumn in the oligomerization recovery zone for separating a gasolinestream from a distillate stream, the FCC zone being in communicationwith the distillate separator column and an overhead line of thedistillate separator being in communication with a gasoline tank or agasoline blending line. An embodiment of the invention is one, any orall of prior embodiments in this paragraph up through the sixthembodiment in this paragraph wherein the FCC zone is in communicationwith a bottom line of the distillate separator column. An embodiment ofthe invention is one, any or all of prior embodiments in this paragraphup through the sixth embodiment in this paragraph wherein the FCC zonecomprises a reactor riser which is in communication with the hydrocarbonfeed line and the bottom line of the distillate separator column. Anembodiment of the invention is one, any or all of prior embodiments inthis paragraph up through the sixth embodiment in this paragraph whereinthe FCC zone comprises a first reactor riser which is in communicationwith the hydrocarbon feed line and a second reactor riser which is incommunication with the bottom line of the distillate separator column.An embodiment of the invention is one, any or all of prior embodimentsin this paragraph up through the sixth embodiment in this paragraphwherein the oligomerization recovery zone further comprises adebutanizer column and the oligomerization zone is in communication witha bottom line of the debutanizer column and the distillate separatorcolumn is in communication with a bottom line of the debutanizer column.

Without further elaboration, it is believed that one skilled in the artcan, using the preceding description, utilize the present invention toits fullest extent. Preferred embodiments of this invention aredescribed herein, including the best mode known to the inventors forcarrying out the invention. The preceding preferred specific embodimentsare, therefore, to be construed as merely illustrative, and notlimitative of the remainder of the disclosure in any way whatsoever.

In the foregoing, all temperatures are set forth in degrees Celsius and,all parts and percentages are by weight, unless otherwise indicated.Pressures are given at the vessel outlet and particularly at the vaporoutlet in vessels with multiple outlets. Control valves should be openedor closed as consistent with the intent of the disclosure.

From the foregoing description, one skilled in the art can easilyascertain the essential characteristics of this invention and, withoutdeparting from the spirit and scope thereof, can make various changesand modifications of the invention to adapt it to various usages andconditions.

The invention claimed is:
 1. An apparatus for making propylenecomprising: an FCC zone for cracking a hydrocarbon feed stream from ahydrocarbon feed line and a distillate recycle stream comprisingdistillate hydrocarbons over an FCC catalyst to produce a crackedproduct stream; an FCC recovery zone in communication with said FCC zonefor recovering a propylene product stream and an oligomerization feedstream comprising C₄ olefins from said cracked product stream; anoligomerization zone in communication with said FCC recovery zone foroligomerizing C₄ olefins in said oligomerization feed stream to producean oligomerate stream; and an oligomerization recovery zone indownstream communication with said oligomerization zone for separatingsaid oligomerate stream; a debutanizer column in said oligomerizationrecovery zone for separating said oligomerate stream into a vaporousoligomerate overhead light stream in a overhead line and a liquidoligomerate bottom stream in a bottom line, the bottom line in upstreamcommunication with the oligomerization zone; a depentanizer column insaid oligomerization recovery zone for separating the first liquidoligomerate bottom stream into an intermediate stream in an intermediateline and a liquid oligomerate bottom product stream in a bottom productline, the bottom product line being in upstream communication with theoligomerization zone; and a distillate separator column in saidoligomerization recovery zone for separating a gasoline stream from adistillate stream, said FCC zone being in communication with saiddistillate separator column.
 2. The apparatus of claim 1 wherein saidFCC zone is in communication with a bottom line of said distillateseparator column.
 3. The apparatus of claim 2 wherein said FCC zonecomprises a reactor riser which is in communication with saidhydrocarbon feed line and said bottom line of said distillate separatorcolumn.
 4. The apparatus of claim 2 wherein said FCC zone comprises afirst reactor riser which is in communication with said hydrocarbon feedline and a second reactor riser which is in communication with saidbottom line of said distillate separator column.
 5. The apparatus ofclaim 1 wherein said FCC zone comprises a reactor riser which is incommunication with said hydrocarbon feed line and said distillateseparator column.
 6. The apparatus of claim 1 wherein said FCC zonecomprises a first reactor riser which is in communication with saidhydrocarbon feed line and a second reactor riser which is incommunication with said distillate separator column.
 7. The apparatus ofclaim 2 further comprising an overhead line of said distillate separatorcolumn in communication with a gasoline tank or a gasoline blendingline.
 8. The apparatus of claim 1 wherein said distillate separationcolumn is in communication with said bottom line of said debutanizercolumn.
 9. An apparatus for making propylene comprising: an FCC zone forcracking a hydrocarbon feed stream in a hydrocarbon feed line and adistillate recycle stream comprising distillate hydrocarbons over an FCCcatalyst to produce spent FCC catalyst and a cracked product stream; aregeneration vessel in said FCC zone for regenerating said spent FCCcatalyst; an FCC product recovery zone in communication with said FCCzone for recovering a propylene product stream and an oligomerizationfeed stream comprising C₄ olefins from said cracked product stream; anoligomerization zone in communication with said FCC product recoveryzone for oligomerizing C₄ olefins in said oligomerization feed stream toproduce an oligomerate stream; and an oligomerization recovery zone indownstream communication with said oligomerization zone for separatingsaid oligomerate stream; a debutanizer column in said oligomerizationrecovery zone for separating said oligomerate stream into a vaporousoligomerate overhead light stream in a overhead line and a liquidoligomerate bottom stream in a bottom line, the bottom line in upstreamcommunication with the oligomerization zone; a depentanizer column insaid oligomerization recovery zone for separating the first liquidoligomerate bottom stream into an intermediate stream in an intermediateline and a liquid oligomerate bottom product stream in a bottom productline, the bottom product line being in upstream communication with theoligomerization zone; and a distillate separator column in saidoligomerization recovery zone for separating a gasoline stream from adistillate stream, said FCC zone being in communication with a bottomline of said distillate separator column.
 10. The apparatus of claim 9wherein said FCC zone comprises a reactor riser which is incommunication with said hydrocarbon feed line and said bottom line ofsaid distillate separator column.
 11. The apparatus of claim 9 whereinsaid FCC zone comprises a first reactor riser which is in communicationwith said hydrocarbon feed line and a second reactor riser which is incommunication with said bottom line of said distillate separator column.12. The apparatus of claim 9 further comprising an overhead line of saiddistillate separator column in communication with a gasoline tank or agasoline blending line.
 13. The apparatus of claim 9 wherein saiddistillate separation column is in communication with a bottom line ofsaid debutanizer column.
 14. An apparatus for making propylenecomprising: an FCC zone for cracking a hydrocarbon feed stream in ahydrocarbon feed line and a distillate recycle stream comprisingdistillate hydrocarbons over an FCC catalyst to produce spent FCCcatalyst and a cracked product stream; a regeneration vessel in said FCCzone for regenerating said spent FCC catalyst; an FCC recovery zone incommunication with said FCC zone for recovering a propylene productstream and an oligomerization feed stream comprising C₄ olefins fromsaid cracked product stream; an oligomerization zone in communicationwith said FCC recovery zone for oligomerizing C₄ olefins in saidoligomerization feed stream to produce an oligomerate stream; and anoligomerization recovery zone in downstream communication with saidoligomerization zone for separating said oligomerate stream; adebutanizer column in said oligomerization recovery zone for separatingsaid oligomerate stream into a vaporous oligomerate overhead lightstream in a overhead line and a liquid oligomerate bottom stream in abottom line, the bottom line in upstream communication with theoligomerization zone; a depentanizer column in said oligomerizationrecovery zone for separating the first liquid oligomerate bottom streaminto an intermediate stream in an intermediate line and a liquidoligomerate bottom product stream in a bottom product line, the bottomproduct line being in upstream communication with the oligomerizationzone; and a distillate separator column in said oligomerization recoveryzone for separating a gasoline stream from a distillate stream, said FCCzone being in communication with said distillate separator column and anoverhead line of said distillate separator being in communication with agasoline tank or a gasoline blending line.
 15. The apparatus of claim 14wherein said FCC zone is in communication with a bottom line of saiddistillate separator column.
 16. The apparatus of claim 15 wherein saidFCC zone comprises a reactor riser which is in communication with saidhydrocarbon feed line and said bottom line of said distillate separatorcolumn.
 17. The apparatus of claim 15 wherein said FCC zone comprises afirst reactor riser which is in communication with said hydrocarbon feedline and a second reactor riser which is in communication with saidbottom line of said distillate separator column.
 18. The apparatus ofclaim 15 wherein said distillate separator column is in communicationwith a bottom line of said debutanizer column.